PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATTTM SERIES
MODEL DCA-150SSJU3
60 Hz GENERATOR
PARTS LIST NO. M3870301104
Revision #0 (11/14/07)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
Download from Www.Somanuals.com. All Manuals Search And Download.
PAGE 2 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
Internet:www.mqpower.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
© COPYRIGHT 2007, 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-150SSJU3 WHISPERWATT AC 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
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DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 3
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TABLE OF CONTENTS
MQ POWER DCA-150SSJU3
COMPONENT DRAWINGS
WHISPERWATTTM GENERATOR
Generator Assembly.................................................. 72-73
Control Box Assembly............................................... 74-77
Engine and Radiator Assembly ................................. 78-81
Output Terminal Assembly......................................... 82-83
Battery Assembly ...................................................... 84-85
Muffler Assembly ...................................................... 86-87
Fuel Tank Assembly .................................................. 88-89
Enclosure Assembly ................................................. 90-95
Rubber Seals Assembly ............................................ 96-97
Nameplate and Decals ............................................ 98-101
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
Diagnostic Display..................................................... 20-36
Generator Control Panel ................................................. 37
Engine Operating Panel ............................................. 38-39
OutputTerminal Panel Familiarization ........................ 40-42
Load Application ............................................................. 43
Generator Outputs .......................................................... 44
Gauge Reading ............................................................... 45
OutputTerminal Panel Connections ........................... 46-47
Setup ......................................................................... 48-51
Generator Start-up Procedure (Manual) ..................... 52-54
Generator Start-up Procedure (Auto Mode) .................... 55
Generator Shut-Down Procedure .................................... 56
Maintenance (Engine) ................................................ 57-58
Maintenance Jacket Water Heater/Battery Charger ........ 59
Maintenance (Trailer) ................................................. 60-63
TrailerWiring Diagram ..................................................... 64
Generator Wiring Diagram ............................................... 65
Engine Wiring Diagram ................................................... 66
GeneratorTroubleshooting .............................................. 67
Engine ControllerTroubleshooting ................................... 68
Explanation of Code in Remarks Column ....................... 70
Suggested Spare Parts .................................................. 71
Terms and Condition of Sale — Parts .......................... 102
Specification and part
NOTE
number are subject to
change without notice.
PAGE 4 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
Dealeraccountnumber
❒
❒
❒
❒
❒
❒
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
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
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: [email protected]
Internet: www.mqpower.com
800-421-1244
FAX: 310-632-2656
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
Standard
orders
Stock orders
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
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 310-638-8046
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-638-8046
FAX: 310-638-8046
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MQPOWER
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
INTERNET:www.mqpower.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 5
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DCA-150SSJU3 — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA-150SSJU3
Revolving field, self ventilated, open protected type synchronous
generator
Armature Connection
Phase
Star with Neutral
3
Zig Zag
Single
Standby Output
Prime Output
Voltage
165 KVA (132 KW)
150 KVA (120 KW)
240V or 480V
95.7 KW
87 KW
240/120V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1.0
Single Phase, 60 Hz
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
Type
JOHN DEERE 6068HF285
4 Cycle, water-cooled, direct injection, turbo-charged,
air to air intercooled
No. of Cylinders
Bore x Stroke
Rated Output
6 cylinders
4.19 in. x 5 in. (106 mm x 127 mm)
216 HP/1800 rpm
Displacement
415 cu. in. (6.8 liters)
Electric
Starting
Fuel Tank Capacity
Coolant Capacity
Lube Oil Capacity
69 gal. (260 liters)
4.6 gal. (17.5 liters)
8.19 gal. (31 liters)
9.0 gal. (33.9 L)/hr at full load
5.2 gal. (19.7 L)/hr at 1/2 load
7.1 gal. (26.9 L)/hr at 3/4 load
3.0 gal. (11.5 L)/hr at 1/4 load
Fuel Consumption
Battery
Fuel
4D (CCA 0° F 925A) x 1
#2 Diesel Fuel
PAGE 6 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — DIMENSIONS (TOP, SIDE AND FRONT)
TABLE 3. DIMENSIONS
Reference
Dimension ft. (mm.)
Reference Letter
Dimension ft. (mm.)
Letter
A
B
C
D
E
35.03 in. (890 mm.)
35.03 in. (890 mm.)
39.76 in. (1,010 mm.)
39.76 in. (1,010 mm.)
42.12 in. (1,070 mm.)
F
G
H
125.98 in. (3,200 mm.)
59.06 in. (1,500 mm.)
47.24 in. (1,200 mm.)
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DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 7
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DCA-150SSJU3 — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
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".
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.
This Owner's Manual has been
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power Model DCA-150SSJU3
Whisperwatt™ Generator.
WARNING - LETHAL EXHAUST GASES
NOTE
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH if inhaled. NEVER operate this
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
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.
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.
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.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING
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.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
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!
PAGE 8 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
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
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the MPEC control switch
in the OFF/RESET position when the
generator is not in use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
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.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
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DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 9
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DCA-150SSJU3 — RULES FOR SAFE OPERATION
■
■
ALWAYS check the machine for loosened threads or bolts
before starting.
DANGER - READTHIS 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.
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.
The following safety guidelines should always be used when
operating the DCA-150SSJU3Whisperwatt™ AC Generator.
HighTemperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.
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.
■
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
■
■
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.
carbon monoxide gas.
■
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
NEVER run engine without air filter.Severe engine damage
may occur.
DO NOT leave the generator running in the manual mode
unattended.
NEVER operate this equipment under the influence or
drugs or alcohol.
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.
PAGE 10 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
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.
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
The following safety recommendations should also be
followed:
terminals, insufficient tightening of the terminal connections
WET
HANDS
may cause damage to the generator
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
and electrical shock.
NEVER grab or touch a live power
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.
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.
■
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
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
■
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 6.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
is being transfer to a load.
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DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 11
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DCA-150SSJU3 — RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
■
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:
can cause severe injury or even death through physical
contact with live circuits. Turn all circuit breakers OFF
■
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation, always wear safety
glasses.
before performing maintenance on the generator.
■
■
■
■
NEVER lubricate components or attempt service on a
running machine.
Use well insulated gloves when picking up the battery.
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
DANGER - EXPLOSION HAZARDS
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
The risk of an explosion exists when performing service
on the battery.To avoid severe injury or DEATH:
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
DO NOT drop the battery.There
is the possibility of risk that the
battery may explode.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always
replace broken parts.
■
DO NOT expose the battery to
open flames, sparks, cigarettes
etc.The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
■
ALWAYS keep the battery charged. If the battery is not
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.
charged a buildup of combustible gas will occur.
■
■
ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■
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.
■
■
In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
■
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.
PAGE 12 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — RULES FOR SAFE OPERATION
Towing &Transporting Safety
■
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.
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.
■
■
■
Place chock blocks underneath wheel to prevent rolling,
while parked.
The following list of safety precautions should be followed
when towing your generator:
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.
CAUTION - FOLLOWTOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting Department of
Transportation (DOT) SafetyTowing Regulations, before
towing your generator.
■
■
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.
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
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.
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.
■
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating.”
■
■
Avoid sharp turns to prevent rolling.
DO NOT transport generator with fuel in tank.
■
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
Emergencies
■
■
■
ALWAYS know the location of the
nearest fire extinguisher.
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 know the location of the
nearest and first aid kit.
■
■
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS know the location of the
nearest phone or keep a phone on
the job site, in case of emergencies.
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
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.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
z
z
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 13
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DCA-150SSJU3 — GENERATOR DECALS
The DCA-150SSJU3 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
PAGE 14 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 15
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DCA-150SSJU3 — INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 16 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — INSTALLATION
Outdoor Installation
Generator Grounding
Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to
bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH
generator is on secure level ground so that it cannot slide or ground.
shift around. Also install the generator in a manner so that
Article 250 (Grounding) of the National Electrical Code (NEC)
the exhaust will not be discharged in the direction of nearby
provides guide lines for proper grounding and specifies that
homes.
the cable ground shall be connected to the grounding system
The installation site must be relatively free from moisture of the building as close to the point of cable entry as
and dust. All electrical equipment should be protected from practical.
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
grounding requirements:
NEC articles 250-64(b) and 250-66 set the following
Foreign materials such as dust, sand, lint and abrasive
1. Use one of the following wire types to connect the
materials have a tendency to cause excessive wear to
generator to earth ground.
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
CAUTION - EXHAUST HAZARD
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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
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.
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
NOTE
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.
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 17
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DCA-150SSJU3 — GENERAL INFORMATION
Open Delta Excitation System
DCA-150SSJU3Whisperwatt™ Series Familiarization
Generator
The DCA-150SSJU3 generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
The MQ Power Model DCA-150SSJU3 is a 120 kW generator system consist of an electrically independent winding wound
among stationary windings of the AC output section.
(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.
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.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■
■
■
■
■
■
■
■
■
■
■
Tachometer
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.
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Engine Speed Switch
Panel Light/Panel Light Switch
Auto ON/OFF Engine Controller (MPEC)
Preheat Lamp
Warning Lamp
Emergency Stop Lamp
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.
Generator Control Panel
The “Generator Control Panel” is provided with the following:
■
■
■
■
■
■
■
■
Frequency Meter (Hz)
Engine
AC Ammeter (Amps)
The DCA-150SSJU3 is powered by a 6 cylinder, water
cooled, direct injection, turbocharged John Deere
6068HF285 Turbo Diesel Engine. This engine is designed
to meet every performance requirement for the generator.
Reference Table 1 for engine specifications.
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 400 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
■
■
■
■
■
■
■
■
Automatic Voltage Regulator
Diagnostic Display
Current Transformer
Over-Current Relay
Electric Governor System
Voltage Rectifer
The electric governor system controls the RPMs of the en-
gine. When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
Starter Relay
Engine Controller (Computer Controlled)
Voltage Selector Switch
Extension Cables
Output Terminal Panel
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 6) as a guide
for selecting proper extension cable size.
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)
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DCA-150SSJU3 — MAJOR COMPONENTS
mponents
mbly
y
8
Generator Assembly
9
Circuit Breaker Assembly
Diagnostic Display Assembly
Generator/Engine Control Panel Assembly
1
10
11
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
3. Right Arrow Button – Press this button to scroll through
the screen either moving the parameter selection toward
the right or downward.
4. Enter Key Button – Press this button to select the
parameter that is highlighted on the screen.
5. Emergency Stop LED – When lit (RED) indicates a
major fault has occured. This condition will shudown
the generator.
6. Warning LED – When lit (AMBER), indicates a engine
parameter has exceeded its limits (minor fault). The
generator will still run in this condition.
7. Display Screen – Graphical backlight LCD screen. Back
Figure 6. Diagnostic Display Panel
lighting is controlled via menu or external dimmer
potentiometer. The display can show either a single
parameter or a quadrant display showing four parameters
simultaneously.
The diagnostic display panel located inside the control box
on the generator (Figure 6) is designed to meet the needs
for instrumentation and control of electronically controlled
engine communication using the SAEJ1939 Controller Area
Network (CAN). This diagnostic display is a multifunction
tool that enables equipment operators to view many different
engine parameters and service codes.
8. Diagnostic Switch – When placed in the ON position,
will activate the diagnostic display panel.
9. CAN Diagnostic Connector – Controller Area Network
connector. This connector outputs diagnostic error
codes. Connect a scanner or similar device into this
connector to read error codes.
The keypad on the diagnostic display panel is a capacitive
touch sensing system.There are no mechanical switches to
wear or stick. This keypad (display unit) will operate in
extreme hot or cold weather conditions.
Display Parameters
The following are some of the engine and transmission
parameters displayed on the diagnostic disply panel.
Other components in the system are microprocessor-based
components for displaying critical engine data broadcast by
an electronic engine or transmission’s Engine Control Unit
(ECU): engine RPM, oil pressure, coolant temperature,
system voltage, etc., and a combination audible alarm and
relay unit for warning and shutdown annunciation.
■
■
■
■
■
■
■
■
■
■
■
■
■
Engine RPM’s
Engine Hours
System Voltage
% Engine Load at current RPM
CoolantTemperature
Oil Pressure
Fuel Economy
Current Fuel Consumption
Throttle Position
Engine Manifold AirTemperature
Active Service Codes
Set Units for Display (English or Metric)
English Configuration Parameters.
The Engine Control Unit (ECU) used with this generator
diagnosis engine faults that arise with the the engine control
system and the engine itself. Engine faults can be determined
by viewing the DiagnosticTrouble Codes (Active Fault Codes)
which are displayed on the Diagnostic Display Panel. See
the John Deere Engine Operator’s Manual for a complete
listing of active fault codes and countermeasures.
The following definitions describe the controls and functions
of the Diagnostic Display Panel (Figure 6).
1. Menu Button – Press this button to enter or exit menu
screens.
2. Left Arrow Button– Press this button to scroll through
the screen either moving the parameter selection toward
the left or upward.
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
First Time Start Up
2. The first seven items of the “Main Menu” will be
displayed.Touching the“Arrow Buttons”will scroll through
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence.Once the “Wait to
Start”message is no longer displayed the operator may
start the engine. Note: Displays only when SAE J1939
message is supported by engine manufacturer.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
WAIT TO
START
PREHEAT
4. Touch the Arrows” to scroll to the desired menu item or
touch “Menu” to exit the Main menu and return to the
engine parameter display.
3. Once the engine has started the single engine parameter
is displayed.
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
Selecting a Language
Main Menu Navigation
1. Starting at the single or four engine parameter display,
touch “Menu”.
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted touch
the “Enter” button.
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
GO TO 1-UP DISPLAY
LANGUAGES
14.2
57 PSI
STORED CODES
ENGINE CONFG
BATT VOLT
OIL PRES
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
4. If the word “MORE” appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.
2. The language choices will be displayed. Use the “Arrow”
buttons to scroll through the selections and touch “Enter”
to make a selection.
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
3. Now that you have selected the language, touch the
“Menu” button to return to the main menu display.
5. Touch the “Menu Button to return to the main menu.
Stored Fault Codes
1
of
x
1. Starting at the single or the four engine parameter
display touch the “Menu button”.
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1000 RPM
98%
0
3000
ENG RPM
1500
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
GO TO 1-UP DISPLAY
2. The main menu will pop up on the display.Use the“Arrow
Buttons”to scroll through the menu until the Stored Fault
Codes is highlighted.
1000 RPM
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENG RPM
LOAD RPM
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Engine Configuration Data
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button” to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters).
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
First Time Start Up
2. The first seven items of the “Main Menu” will be
displayed.Touching the“Arrow Buttons”will scroll through
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence.Once the “Wait to
Start”message is no longer displayed the operator may
start the engine. Note: Displays only when SAE J1939
message is supported by engine manufacturer.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
WAIT TO
START
PREHEAT
4. Touch the Arrows” to scroll to the desired menu item or
touch “Menu” to exit the Main menu and return to the
engine parameter display.
3. Once the engine has started the single engine parameter
is displayed.
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
Selecting a Language
Main Menu Navigation
1. Starting at the single or four engine parameter display,
touch “Menu”.
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted touch
the “Enter” button.
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
GO TO 1-UP DISPLAY
LANGUAGES
14.2
57 PSI
STORED CODES
ENGINE CONFG
BATT VOLT
OIL PRES
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
4. If the word “MORE” appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.
2. The language choices will be displayed. Use the “Arrow”
buttons to scroll through the selections and touch “Enter”
to make a selection.
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
3. Now that you have selected the language, touch the
“Menu” button to return to the main menu display.
5. Touch the “Menu Button to return to the main menu.
Stored Fault Codes
1
of
x
1. Starting at the single or the four engine parameter
display touch the “Menu button”.
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1000 RPM
98%
0
3000
ENG RPM
1500
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
GO TO 1-UP DISPLAY
2. The main menu will pop up on the display.Use the“Arrow
Buttons”to scroll through the menu until the Stored Fault
Codes is highlighted.
1000 RPM
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENG RPM
LOAD RPM
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Engine Configuration Data
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button” to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters).
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
2. The main menu will pop up on the display.Use the“Arrow
FAULTS ANDWARNINGS
Buttons” to scroll through the menu until the “Engine
Configuration” menu item has been highlighted.
Auxiliary Gage Fault
1. During normal operation the single or four parameter
screen will be displayed.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
3. Once the “Engine Configuration” menu item has been
highlighted touch the “Enter Button” to view the engine
configuration data.
2. The PVA Series of auxiliary gages can be attached to
the PowerView.These auxiliary gages communicate with
the Modbus master PowerView via a daisy-chained RS-
485 port. If at any time during system initialization or
normal operation an auxiliary gage should fail, the single
or four parameter screen will be replaced with the “MLink
Gage Fault” message.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4. Use the “Arrow Buttons” to scroll through the engine
configuration data.
1
of
x
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
HIDE
ENGINE SPEED PT 1
1800 RPM
MORE
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display, touch the “Enter Button”.
5. Touch the “Menu Button” to return to the main menu.
1
of
x
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
HIDE
ENGINE SPEED PT 1
1800 RPM
MORE
4. The display will return to the single or four parameter
screen.
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
!
3000
1000 RPM
98%
ENG RPM
0
LOAD RPM
1500
1800 RPM
ENG RPM COOL TEMP!
!
14.2
57 PSI
BATT VOLT
OIL PRES
!
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
!
!
!
Indicates Auxiliary Gage Fault
4. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter Button”.
Indicates Fault Warning
Indicates Derate or Shutdown Condition Fault
5. Touching the “Enter Button” will redisplay the hidden
fault. Touching the “Enter Button” once again will hide
the fault and return the screen to the single or four
parameter display.NOTE:The fault can only be cleared
by correcting the cause of the fault condition.
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1
of
x
5. The display will return to the single or four parameter
display but the display will contain the “Active Fault”
warning icon.Touching the “Enter Button” will redisplay
the hidden fault.
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
HIDE
!
1000 RPM
98%
0
ENG RPM
1500
3000
LOAD RPM
Active Fault Codes
1800 RPM
ENG RPM COOL TEMP!
!
14.2
57 PSI
BATT VOLT
OIL PRES
1.
During normal operation the single or four parameter
screen will be displayed.
!
1000 RPM
98%
125°F
COOL TEMP
1000 RPM
ENG RPM
ENG RPM
LOAD RPM
6. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four parameter
display.
143°F
OIL TEMP
14.2
57 PSI
57 PSI
BATT VOLT
OIL PRES
OIL PRES
1
of
x
WARNING
SPN110 FMI10
HIGH COOLANT TEMP
2. When the PowerView receives a fault code from an
engine control unit the single or four parameter screen
will be replaced with the “Active Fault Codes”message.
MORE
HIDE
1
of
x
WARNING
7. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
3. If the word “MORE” appears above the “Arrow Buttons”,
there are more active fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next “Active
Fault Code”.
GO TO 1-UP DISPLAY
1000 RPM
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENG RPM
LOAD RPM
!
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
5. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four parameter
Shut Down Codes
1. During normal operation the single or four parameter
screen will be displayed.
display.
1
of
x
SHUTDOWN
1000 RPM
98%
SPN110 FMI10
HIGH COOLANT TEMP
ENG RPM
LOAD RPM
0
3000
1500
MORE
HIDE
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
2. When the diagnostic display receives a severe fault
code from an engine control unit the single or four
parameter screen will be replaced with the “Shutdown”
message.
1
of
x
SHUTDOWN
!
1000 RPM
98%
0
1500
3000
ENG RPM
LOAD RPM
SPN110 FMI10
HIGH COOLANT TEMP
1800 RPM
ENG RPM COOL TEMP!
!
14.2
57 PSI
BATT VOLT
OIL PRES
MORE
HIDE
!
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter Button”.
Backlight Adjustment
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
1
of
x
SHUTDOWN
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1000 RPM
98%
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
4. The display will return to the single or four parameter
display, but the display will contain the “Shut Down”
icon.Touching the“Enter Button”will redisplay the hidden
fault.
2. The main menu will pop up on the display.Use the “Arrow
Buttons” to scroll through the menu until the “Adjust
Backlight” is highlighted.
!
1000 RPM
98%
0
1500
3000
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP!
!
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
14.2
57 PSI
BATT VOLT
OIL PRES
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
Contrast Adjustment
3. Once the “Adjust Backlight” menu item has been
highlighted touch the “Enter Button” to activate the
“Adjust Backlight” function.
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
ADJUST BACKLIGHT
BATT VOLT
OIL PRES
4. Use the “Arrow Buttons” to select the desired backlight
intensity.
2. The main menu will pop up on the display.Use the“Arrow
Buttons” to scroll through the menu until “Adjust Contrast”
is highlighted.
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
5. Touch the “Menu Button” to return to the main menu.
3. Once the “Adjust Contrast” menu item has been
highlighted touch the “Enter Button” to activate the
“Adjust Contrast” function.
ADJUST BACKLIGHT
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
4. Use the “Arrow Buttons” to select the desired contrast
intensity.
GO TO 1-UP DISPLAY
1000 RPM
98%
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENG RPM
LOAD RPM
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
ADJUST CONTRAST
5. Touching the “Menu Button” will take you back through
the menus.
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
Select Units
5. Touch the “Enter Button” to select the highlighted units.
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
ENGLISH
METRIC KPA
METRIC BAR
1000 RPM
98%
ENG RPM
0
3000
LOAD RPM
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Touch the “Menu Button” to return to the “Main Menu”.
2. The main menu will pop up on the display.Use the arrow
buttons to scroll through the menu until the “Select
Units” is highlighted.
ENGLISH
*
METRIC KPA
METRIC BAR
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
7. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
1000 RPM
98%
STORED CODES
ENGINE CONFG
ENG RPM
LOAD RPM
3. Once the “Select Units” menu item has been highlighted
touch the “Enter Button” to access the “Select Units”
function.
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
Setup 1- Up Display
ADJUST BACKLIGHT
1. Starting at the single engine parameter display, touch
the “Menu Button”.
4. Use the arrows to highlight the desired units. “English”
for imperial units i.e. PSI,”F or Metric kPa, Metric Bar
for IS units i.e. kPa, Bar, “C.
1000 RPM
98%
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Setup 1-up Display” is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
3. Once the “Setup 1-up Display” menu icon has been 7. A message indicating the “Single Engine” parameter
highlighted touch the “Enter Button” to access the “Setup
1-up display” function.
display parameters are reset to the factory defaults will
be displayed, then the display will return to the “Custom
Setup” menu.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
RESTORED TO
DEFAULTS
ADJUST BACKLIGHT
4. Three options are available for modification of the 1-Up
display.
8. Custom Setup- To perform a custom setup of the 1-Up
Display, use the arrow buttons to scroll to and highlight
“Custom Setup” on the display.
a). Use defaults-This option contains a set of engine
parameters: Engine Hours, Engine RPM. System
Voltage, BatteryVoltage, % Engine Load at Current
RPM, Coolant Temperature, Oil Pressure.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
b). Custom Setup- This option allows for the
modification of what parameter, the number of
parameters, and the order in which the parameters
are being displayed.
9. Touching the “Enter Button” will display a list of engine
parameters.
c). Automatic scan - Selecting the scan function will
cause the 1-Up Display to scroll through the
selected set of parameters one at a time,
momentarily pausing at each.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
5. Use Defaults- To select “Use Defaults” use the arrow
buttons to scroll to and highlight “Use Defaults” in the
menu display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
10. Use the “Arrow Buttons” to scroll to and highlight a
selected parameter (parameter with a # symbol to right
of it).
1
3
2
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
This number indicates
the order of display for the
parameters and that the
parameter is selected
for display.
6. Touch the “Enter Button” to activate the “Use Defaults”
function.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
11. Touch the “Enter Button” to deselect the selected 16. Touching the “Enter Button” toggles the “Automatic
parameter removing it from the list of parameters being
displayed on the 1-up display.
Scan” function on.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
1
3
2
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
17. Touching the “Enter Button”again toggles the “Automatic
Scan” function off.
12. Use the “Arrow Button” to scroll and highlight the desired
parameter that has not been selected for display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
Note that the numbers
now indicate the new order
of display for the parameters.
18. Once the “Use Defaults”, “Custom Setup” and “Automatic
Scan” functions have been set touch the “Menu Button”
to return to the main menu.
13. Touch the “Enter Button” to select the highlighted
parameter for inclusion in the Single Engine Parameter
Display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
3
19. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
14. Continue to scroll and select additional parameters for
the custom 1-up Display. Touch the “Menu Button” at
any time to return to the “Custom Setup” menu.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
0
3000
1500
15. Automatic Scan- Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time. Use the “Arrow Buttons” to
scroll to the “Automatic Scan” function.
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
ADJUST BACKLIGHT
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
Setup 4-Up Display
5. The “Use Defaults” screen will be displayed during the
resetting period then will automatically return to the
“Setup 4- Up Display” menu.
1. From the single or four engine parameter display touch
the “Menu Button”.
RESTORED TO
DEFAULTS
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Select the “4-Up Custom Setup” from the “4-Up Setup”
menu.
2. The main menu will pop up on the display.Use the“Arrow
Buttons” to scroll through the menu until the “Setup 4-
Up Display” is highlighted.
USE DEFAULTS
CUSTOM SETUP
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
7.The quadrant with the backlit parameter value is the current
selected parameter.Use the “Arrow Buttons”to highlight
the parameter value in the quadrant you wish to place a
new parameter.
3. Once the “Setup 4-Up Display” menu item has been
highlighted touch the “Enter Button” to activate the
“Setup 4- Up Display” menu.
USE DEFAULTS
CUSTOM SETUP
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
8.Touch the“Enter Button”and a list of parameters will appear.
4. Touch the “Enter Button” to activate the “Use Defaults”
function. This action will reset the unit to the factory
default.
125°F
COOL TEMP
1000 RPM
ENG RPM
14.2
BATT VOLT
57 PSI
OIL PRES
USE DEFAULTS
CUSTOM SETUP
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
9. The parameter that is highlighted is the selected 14. Touch the “Menu Button” to return to the main menu.
parameter for the screen. Use the “Arrow Buttons” to
highlight the new parameter to be placed in the quadrant
selected in the previous screen.
125°F
COOL TEMP
1000 RPM
ENG RPM
143°F
OIL TEMP
57 PSI
OIL PRES
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
3
1
The number to the right
of the parameter indicates
the quadrant in which it
is displayed.
2
1= Upper Left Quadrant
4
2
3
4
=
=
=
Lower Left Quadrant
Upper Right Quadrant
Lower Right Quadrant
15. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
10. Touch the “Enter Button” to change the selected
parameter in the quadrant to the new parameter.
GO TO 1-UP DISPLAY
125°F
ENGINE CONFG
COOL TEMP
STORED CODES
1000 RPM
ENG RPM
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
143°F
OIL TEMP
57 PSI
OIL PRES
ADJUST BACKLIGHT
ENGINE SPEED
ENGINE HOURS
3
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
1
2
4
Utilities (information and troubleshooting)
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
11. Use the “Menu Button” to return to the “4-Up Custom
Setup” screen.
125°F
COOL TEMP
1000 RPM
0
3000
1500
ENG RPM
1800 RPM
ENG RPM COOL TEMP
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
3
1
143°F
OIL TEMP
57 PSI
OIL PRES
2
4
Note the number to
the right of the selected
parameter indicating that the
parameter is now assigned
to that display location
2.The main menu will be displayed. Use the “Arrow Buttons”
to scroll through the menu until the “Utilities” is
highlighted.
12. The parameter in the selected quadrant has changed
to the parameter selected in the previous screen.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
125°F
COOL TEMP
1000 RPM
ENG RPM
ADJUST BACKLIGHT
UTILITIES
143°F
OIL TEMP
57 PSI
OIL PRES
3. Once the “Utilities” menu item has been highlighted, touch
the “Enter Button” to activate the “Utilities” functions.
13. Repeat the parameter selection process until all spaces
are filled.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
4. Touch “Select” to enter the “Gage Data” display. When 8. When the gage data has cleared, the display
“Gage Data” is selected the PowerView will
communicate with the analog gages at a fixed rate of
38.4k Band, 8 data bits, no parity check, 1 stop bits,
half duplex.
automatically returns to the “Utilities” menu. Scroll to
“Software Version”.Touch “Select” to view the software
version currently in the diagnostic display.
SOFTWARE
VERSION
MURPHY: X.XX
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
ADJUST BACKLIGHT
DEMO MODE ON
9. Touch “Menu” to return to “Utilities”. Highlight Fault
Conversion” using the “Arrows”.Touch “Select” to enter
the Fault conversion menu.
5. Use the “Arrow Buttons” to scroll through the items or
touch “Menu” to return to the “Utilities” menu.
1
of
x
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT CONVERSION
ENGINE OIL PRESSURE
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
6. Touch “Menu Button” to return to the “Utilities” menu.
10. Use the “Arrows” to scroll to and highlight the desired
version then touch “Select”. An asterisk denotes which
version is currently selected.
1
of
x
ENGINE OIL PRESSURE
NOTE: There are four (4) different methods for converting
fault codes. The diagnostic display always looks for J1939
Version 4 and can be set to read the code as one of three (3)
other J1939 versions if Version 4 is not being used. Most
engine ECU’s use Version 4, therefore in most cases
adjustment of this menu option will not be required.
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
7. Use the “Arrows” to highlight Remove All Gages”.Touch
“Select” to clear gage data from memory. It takes a
moment to clear all gages.
Upon receiving an unrecognizable fault, change to a different
J1939 Version. If the fault SPN does not change when the
version is changed, the ECU generating the fault is using
Fault Conversion method 4. If the SPN number does not
change but is still unrecognizable, try changing to another
J1939 Version not yet used and continue to check the SPN
number.
CLEARING GAGES
PLEASE WAIT
J1939 VERSION 1
J1939 VERSION 2
J1939 VERSION 3
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
11. Touch the “Menu” button to return to “Utilities” menu. 4. Use the “Arrows” to scroll down to and highlight either
Touch the “Menu button again to return to the “Main”
menu.
the “Slave Active or Master Active” modes. Touch the
“Enter” button to toggle between master and slave.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
ADJUST BACKLIGHT
UTILITIES
MODBUS SETUP
5. Use the “Arrows” to scroll to the “Serial Port” menu to
highlight it, then touch “Enter”.
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
1000 RPM
98%
0
3000
1500
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Use the “Arrow” button to scroll to each selection to
configure the MODBUS values for your application.
2. The main menu will be displayed. Use the “Arrow
Buttons” to scroll through the menu until the “Utilities”
is highlighted, then touch “Enter”.
BAUD RATE
PARITY
DATA BITS
STOP BITS
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
3. Once in the “Utilities” menu use the “Arrows” to scroll
through the menu until the “Modbus Setup” menu is
highlighted, then touch “Enter”.
7. When finished, touch “Menu” to return to the previous
screen.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
1
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DCA-150SSJU3 — DIAGNOSTIC DISPLAY
GLOSSARY (Troubleshooting information)
CANBUS FAILURE
Diagnostic Display has not received any CAN messages for at least 30 seconds.
NO DATA
Diagnostic Display has not received the particular message being displayed for at least 5 seconds.
NOT SUPPORTED
Diagnostic Display has received a message from the ECU stating the displayed message is not supported
DATA ERROR
Diagnostic Display has received an error message from the ECU for the displayed message.
EMPTY
No parameter selected for this 4- UP quadrant.
WAITTO START PREHEATING
This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING
The ECU did not respond to the PowerView request.
NO GAGE DATA
The Diagnostic Display has no record of connected gages to the RS485 bus.
DISPLAY NOT VISIBLE
Press and hold the “Menu” button for approximately 3 seconds.
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DCA-150SSJU3 — GENERATOR CONTROL PANEL
Figure 7. Generator Control Panel
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 definitions below describe the controls and functions of
the DCA-150SSJU3 Generator Control Panel (Figure 7).
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
The Control Box is equipped with the following major
components:
2. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
■
■
■
■
■
■
Over-Current Relay
Voltage Rectifer (AVR)
Starter Relay
CurrentTransformer
Voltage Selector Switch
Three Phase Circuit Breaker
3. 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.
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
4. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
5. ACVoltmeter – Indicates the output voltage present at
the U,V, and W Output Terminal Lugs.
In the event of a short circuit or over current condition, it will
automatically trip the 400 amp main breaker.
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.
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).
7. Main Circuit Breaker – This three-pole, 400A main
breaker is provided to protect the the U,V,andW Output
Terminal Lugs from overload.
1
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DCA-150SSJU3 — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-150SSJU3 Engine Operating Panel (Figure 8).
Figure 8. Engine Operating Panel
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.
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.
2. Panel Light Switch – When activated will turn on control
6. Fuel Gauge - Indicates amount of diesel fuel available.
panel light.
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.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. (241~448
kPa).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.
8. Engine Speed Switch –This switch controls the speed
4. Water Temperature Gauge – During normal operation
this gauge be should read between 180° and 230°F.(82° C
and 110° C
of the engine (low/high).
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DCA-150SSJU3 — ENGINE OPERATING PANEL
9. Pre-Heat Lamp – When lit, indicates engine is in the
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.
pre-heating mode (for starting during cold weather
operating conditiions). When lamp goes off engine is
ready for starting.
10. Warning Lamp –This lamp will illuminate when a critical
engine fault has occured.
If the generator is to be connected to a building’s AC
power source via an automatic transfer switch
(isolation), place the switch in the AUTO position. In
this position, should an outage occur, the automatic
transfer switch (ATS) will start the generator
automatically via the generator’s auto-start contacts
connected to the ATS’s start contacts. Please refer to
your ATS installation manual for further instructions for
the correct installation of the auto-start contacts of the
generator to the ATS.
11. Emergency Stop Lamp –This lamp will illuminate when
the emergency stop button has been pressed or a critical
engine fault has occured.
12. Diagnostic Display – This display monitors crtical
engine functions. If any abnormal conditions occur, an
Active Fault Code will be displayed. This diagnostic
display can be located inside the control box.
13. 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.
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.
During cranking cycle , The
MPEC will attempt to crank the
engine for 10 seconds before
disengaging.
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.
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.
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
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 safe operating speed.
1
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DCA-150SSJU3 — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 9) shown below is located The “OutputTerminal Panel ” (Figure 8) is provided with the
on the right-hand side (left from control panel) of the generator. following:
Lift up on the cover to gain access to receptacles and terminal
lugs.
■
■
■
■
■
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 100V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O” and “Ground”
are considered bonded grounds.
NOTE
Figure 9. Output Terminal Panel
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DCA-150SSJU3 — OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
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
OutputTerminal Lugs.
There are two 120VAC, 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.
Turn the voltage regulator control knob (Figure 12) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob counter-
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the Test Button (See Figure 10) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 12.Voltage Regulator Control Knob
Removing the Plastic Face Plate (HardWire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 13). 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 10. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 240/139V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 11) provided on the output
terminal panel.These receptacles can only be accessed
when the voltage change-over board is configured for three-
phase 240 operation.
Figure 13. Plastic Face Plate (Output Terminal Lugs)
Figure 11. 240/139VTwist-Lock
Auxiliary Receptacles
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DCA-150SSJU3 — OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
Connecting Loads
An over current relay (Figure 15) 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 cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Loads can be connected to the generator by the Ouput
Terminal Lugs or the convienience receptacles (Figure 14).
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, 400A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Figure 15. Over Current Relay
Figure 14. Connecting Loads
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DCA-150SSJU3 — LOAD APPLICATION
Single Phase Load
Three Phase Load
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase power
and equipment to insure the wattage, amperage, frequency
,
use the following equation:
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.
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybedeterminedbymultiplying
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.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 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 6.
Table 5. Power Factor By Load
Type Of Load
Power Factor
■
■
■
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.
Single-phase induction motors
Three-phase induction motors
0.4 - 0.75
0.65 - 0.
1.0
8
5
Electric heaters, incandescent
lamps
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.
Fluorescent lamps, mercury lamps
0.4 - 0.9
1.0
Electronic devices, communication
equipment
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
0.8
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Current in
Amperes
At 100
Volts
At 200
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
DANGER - ELECTRICAL SYSTEM HAZARDS
7.5
10
15
20
900
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.
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-150SSJU3 — GENERATOR OUTPUTS
Generator Amperage
Generator OutputVoltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by apply-
ing jumpers (6) to the voltage change-over board (Figure 15).
To obtain some of the voltages as listed in Table 6 (see
below) will require a fine adjustment using the voltage regu-
lator (VR) control knob located on the control panel.
Tables 8 and 9 describe the generator’s current output capa-
bility for both 1Ø-phase and 3Ø phase applications.
Table 8. Generator Ampere Ratings
⎯
1∅
kW
10
120V
83
240V
Voltage Change-Over Board
233
317
400
483
568
650
500
The voltage change-over board (Figure 16) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
20
166
333
500
667
833
1,000
40
60
80
100
120 (Max)
Table 9. Generator Ampere Ratings
⎯
3∅
KVA
25
240V
60
480V
Figure 16. Voltage Change-Over Board
CAUTION - CHANGINGVOLTAGES
30
54
45
108
144
168
197
241
301
361
60
72
70
84
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
82
99
100
125
150
120
150
180
Table 7. Voltages Available
Three Phase
208V
220V
240V
416V
440V
254V
480V
277V
(Selectable)
Single Phase
(Selectable)
120V
127V
139V
240V
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DCA-150SSJU3 — GENERATOR OUTPUTS/ GAUGE READING
Maximum Amps
Table 10 shows the maximum amps the generator can pro-
vide. DO NOT exceed the maximum amps as listed.
Table 10. Generator Maximum Amps
Model
DCA150SSJU3
Maximum Amps
33.3 amps (4 wire)
Figure 18. ACVoltmeter Gauge
(Volt reading on W-U Lug)
Figure 17. AC Voltmeter
Change-Over Switch
Rated Voltage
Single Phase
120 Volt
Single Phase
240 Volt
166.7 amps (4 wire)
361 amps
Three Phase
240 Volt
Three Phase
480 Volt
180 amps
How to Read the OutputTerminal Gauge.
Figure 20. AC Ammeter
(Amp reading on U lug)
Figure 19. AC Ammeter
Change-Over Switch
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
When the voltage change-over board (Figure 16) is jumpered
for 3Ø, 240V operation place the AC Voltmeter Change-
Over Switch (Figure 17) to the W-U position and the AC
Ammeter Change-Over Switch (Figure 19) to the U or W
position. Use the AC voltmeter or AC ammeter (Figures 18
and 20) to read the output on the selected leg of the UVWO
terminals.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
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DCA-150SSJU3 — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V Output Terminal Lug Voltages
Various output voltages can be obtained using the Output
Terminal Lugs. The voltages at the terminals are depen-
dent on the position of the Voltage Selector Switch and the
adjustment of the Voltage Regulator Control Knob.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 25.
Use this position for
3Ø-240 or 1Ø120V.
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.
Figure 25. Voltage Selector
Switch 240/139V
3Ø 240/139 Output Terminal Lug Voltages
Three-Phase Position
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 26.
Figure 22. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 23.
Figure 26. Output Terminal Lugs
3Ø-208/120V Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
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 23. Output Terminal Lugs
3Ø-240/139V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
NOTE
Figure 24. Voltage Regulator Knob (139V/240V)
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DCA-150SSJU3 — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal Lug Voltages
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 29.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 29. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 30.
shown in Figure 28.
Figure 28. Output Terminal Lugs
3Ø-480/277V Connections
Figure 30. Output Terminal Lugs
1Ø-240/120V Connections
3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
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DCA-150SSJU3 — SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 400 amp,
main circuit breaker is provided to protect the U,V, and W
OutputTerminals 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.
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.
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 30) on the dipstick. See Table 9 for proper
selection of engine oil.
Refilling the Fuel System
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
Figure 30. Engine Oil Dipstick
This generator has an internal fuel tank located inside the
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31). ALWAYS fill the fuel tanks with clean
fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their
capacities.
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.
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.
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
Figure 31. Internal Fuel Tank System
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DCA-150SSJU3 — SETUP
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
3. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel cap
and fill tank (Figure 33).
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 32).
CAUTION - REFUELINGTHE 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.
Figure 33. 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 34).
Figure 32. Only Fill on Level Ground
NOTE
ONLY! use #2 diesel fuel when
refueling.
Figure 34. Full Fuel Tank
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 35).
Figure 35. Fuel Expansion
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DCA-150SSJU3 — SETUP
Cleaning the Radiator
Coolant (Antifreeze)
John Deere recommends 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
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.
WARNING - BURN HAZARDS
Air Cleaner
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.
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Deere Engine Owner's Manual.
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 12 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.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 36) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
6.4 Gal. (24 liters)
2 Quarts (1.9 liters)
Figure 36. Fan Belt Tension
CAUTION - ROTATING PARTS
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
NEVER place hands near
the belts or fan while the
generator set is running.
Table 13. Anti-Freeze
Operating Temperatures
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
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DCA-150SSJU3 — SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
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.
terminals when the MPEC Control Switch is in either
the MANUAL or AUTO position.ALWAYS make sure that
the MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
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.
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
If the battery cable is connected
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.
incorrectly, electrical damage to the
NOTE
generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
ALWAYS be sure the battery cables (Figure 37) 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.
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.
CAUTION - BATTERY SERVICING SAFETY
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
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.
Figure 37. Battery Connections
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DCA-150SSJU3 — GENERATOR START-UP PROCEDURE (MANUAL)
3. Make sure the the voltage change-over board has
Before Starting
been configured for the desired output voltage.
CAUTION - LETHAL EXHAUST HAZARD
4. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 14. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING - STARTINGTHE GENERATOR
5. 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.
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
6. Close all engine enclosure doors (Figure 40).
The Engine Control Unit (ECU) used with this generator
diagnosis engine faults that arise with the the engine control
system and the engine itself. Engine faults can be determined
by viewing the DiagnosticTrouble Codes (Active Fault Codes)
which are displayed on the Diagnostic Display Panel located
inside the Control Box.
1. Before starting the engine, make sure the diagnostic
switch (Figure 38) on the Diagnostic Display Panel
Assembly is in the “OFF” position.
Figure 40. Engine Enclosure Doors
Starting (Manual)
1. Place the engine speed switch (Figure 41) in the “LOW ”
(down) position
Figure 41. Engine Speed Switch (Low)
2. Place the MPEC Control Switch in the MANUAL
position to start the engine (Figure 42). Observe that the
Warning and Emergency Stop lamps on the Engine
Operating Panel are lit during the initial starting of the
engine. If no abnormal conditions exists, both lamps will
turn off.
Figure 38. Diagnostic Switch (OFF poistion)
2. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 39) in the OFF position prior to starting the engine.
Figure 42. MPEC Control Switch
(Manual Position)
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
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DCA-150SSJU3 — GENERATOR START-UP PROCEDURE (MANUAL)
When the MPEC Control switch is 8. To restart the engine due to error codes, place the MPEC
placed in the manual position,
preheating of the glow plugs will begin
automatically and the preheat lamp
will stay lit until the
Control Switch in the MANUAL position (Figure 42)
NOTE
9. If the engine is running smoothly, place the engine
speed switch (Figure 44) in the “HIGH” (up) position.
glow plugs are warmed. When the preheat
lamp goes off this signals the completion of
the preheating cycle and the starting of the
engine.
Preheat Lamp
Figure 44. Engine Speed Switch (High)
3. If any abnormalities exists, the Warning and
Emergency Stop lamps on the Engine Operating Panel
will be lit.
10.Verify that the Engine Running
status LED on the MPEC unit
(Figure 45) is ON (lit) after the
engine has been started.
4. Place the MPEC Control Switch (Figure 42) in the
OFF/RESET position.
5. Place the Diagnostic ON/OFF switch in the ON
position. Verify that an Active Fault Code message is
being displayed (Diagnostic Display Panel). The fault
code message will continued to be displayed until the
fault has been corrected. Figure 43 shown below is a
typical example of an active fault code message (Low
Radiator Coolant).
Figure 45. Engine Running LED (ON)
11. Observe that the Warning and Emergency Stop lamps
on the Engine Operating Panel are OFF.
12. The generator's frequency meter (Figure 46) should be
displaying the 60 cycle output frequency in HERTZ.
Figure 43. Active Fault Code Message
6. In a situation where several engine problems occur
simultaneously, the word “MORE” appears above the
arrow buttons indicating that there are more fault codes
that need to be viewed. Use the arrow buttons to scroll
to the next active fault code.
Figure 46. Frequency Meter (Hz)
13. The generator's AC-voltmeter (Figure 47) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 48) to increase or decrease the
desired voltage.
If desired, the type of fault code, cause of error and
the countermeasures of the error can be referenced in
a separate engine operator’s manual.
7. Before the engine can be started, the engine fault must
be corrected. Also observe that there are no active
fault codes displayed on the diagnostic panel. If no
fault codes are displayed, place the diagnostic switch
in the OFF position.
Figure 47.Voltmeter
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DCA-150SSJU3 — GENERATOR START-UP PROCEDURE (MANUAL)
18. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 53).
Figure 48.Voltage Adjust Control Knob
14. The ammeter (Figure 49) will
indicate zero amps with no load
applied.When a load is applied, the
Figure 53. Main, Aux. and GFCI
ammeter will indicate the amount of
Circuit Breakers (ON)
current that the load is drawing from
the generator.
19. Observe the generator's ammeter
Figure 49. Ammeter
(Figure 54) and verify it reads the
anticipated amount of current with
(No Load)
respect to the load. The ammeter
will only display a current reading if
15. The engine oil pressure gauge
a load is in use.
Figure 54. Ammeter
(Load)
(Figure 50) will indicate the oil
pressure of the engine. Under
normal operating conditions the oil
pressure is approximately 35 to 65
psi. (241~448 kPa). When starting
the generator
20. The generator will run until manually stopped or an
abnormal condition occurs.
Starting (Auto Mode)
Figure 50. Oil
Pressure Gauge
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.
16. The coolant temperature gauge
(Figure 51) will indicate the
coolant temperature. Under
normal operating conditions the
coolant temperature should be
between 180~230°F (82~110 °C)
Green Zone.
CAUTION - BACKUP GENERATOR USE
Figure 51. Coolant
Temperature Gauge
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.
17. Thetachometergauge (Figure52)
will indicate the speed of the engine
when the generator is operating.
Under normal operating conditions
this speed is approximately 1800
RPM’s.
When the generator is set in the
AUTO mode, the generator will
automically start in the event of
comercial power falling below a
NOTE
Figure 52. Engine
Tachometer Gauge
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
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DCA-150SSJU3 — GENERATOR START-UP PROCEDURE (AUTO MODE)
When starting generator in AUTO mode use the "Manual
Start-up" procedure except where noted (see below).
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. Perform steps 1 through 6 in the Before Starting section
as outlined in the Manual Starting Procedure.
2. Place the engine speed switch (Figure 54) in the HIGH
position
CAUTION - ENGINE SPEED SWITCH
The Engine Speed Switch must be set to the “High”
position when running in the Auto-Start mode.Failing to
set the switch in the proper position can result in damage
to your generator when it turns on.
Figure 54. Engine Speed Switch (High)
3. Place the MPEC Control Switch (Figure 55) in the AUTO
position
When the MPEC Control Switch
is placed in the AUTO position,
the engine glow plugs will be
NOTE
warmed and the engine will start
automatically.
Figure 55. MPEC Control Switch (AUTO)
4. Continue operating the generator as s outlined in the
Manual Start-up procedure (start at step 5).
1
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DCA-150SSJU3 — GENERATOR SHUT-DOWN PROCEDURES
Emergency Shutdown Procedure
WARNING - SHUTTING DOWNTHE GENERATOR
To shutdown the generator in the event of an emergency use
the following procedure:
NEVER stop the engine suddenly except in an emergency.
1. Place the MPEC Control Switch (Figure 57) in the
OFF/RESET position.
CAUTION - DIAGNOSTIC SWITCH
ALWAYS make sure the diagnostic switch is placed in the
OFF position before attempting to shut down the generator.
The OFF/RESET switch on the MEC controller will not
shut down the generator if the diagnostic switch is left in
the ON position.
Normal 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.
2. Place the engine speed switch (Figure 56) in the “LOW ”
(down) position.
Figure 56. Engine Speed Switch (Low)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 57) to the
OFF/RESET position.
Figure 57. 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.
7. Inspect entire generator for any damage or loosening of
components that may have occured during operation.
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DCA-150SSJU3 — MAINTENANCE (ENGINE)
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
1
Replace Engine Oil and Filter *
X
X
Clean Air Filter
ENGINE
Check Fuel Filter/Water Seperator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
X
X
X
X
Clean Radiator and Check Coolant Protection Level*2
3
Replace Air Filter Element *
X
4
Check all Hoses and Clamps *
X
X
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
Check Rotor Rear Support Bearing
X
GENERATOR
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Add "Supplemental Coolant Addatives (SCA'S)" to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the bloby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.
Service Daily
General Inspection
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.
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.UseTable 14 as a general maintenance
guideline Engine Side (Refer to the Engine Instruction
Manual)
Fuel Addition
Air Cleaner
Add diesel fuel (the grade may vary according to season
and locations).
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.
RemovingWater from the FuelTank
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.
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.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with dies1el fuel.
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 57
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DCA-150SSJU3 — MAINTENANCE (ENGINE)
Air Removal
Flushing Out Radiator and Replacing Coolant
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.
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant.Open the
radiator cap while draining. Remove the overflow tank
and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed.DO NOT
clean radiator core with any objects, such as a
screwdriver.
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 31.
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufaturer.
Close radiator cap tightly.
Replacing Oil Filter
WARNING - BURN HAZARDS
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
Generator Storage
Cleaning the Fuel Strainer
For longe term storage of the generator the following is
recommended:
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Replacing Fuel Filter
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Replace the fuel filter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
Vent any air.
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DCA-150SSJU3 — MAINTENANCE (HEATER/CHARGER)
Jacket Water Heater and Internal Battery Charger
120VAC Input Receptacles (OPTIONAL)
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.
This generator can be optionally equipped with two 120VAC,
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.
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger.
NOTE
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 58). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
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.
Figure 58. DCA-150SSJU3Battery Charger &
JacketWater Heater Power Connections
1
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DCA-150SSJU3 — MAINTENANCE (TRAILER )
Trailer Maintenance
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.
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.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
The definitions below describe some of the major components
of a typical trailer that would be used with the DCA-150SSJU3
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
Whisperwatt
™
Generator.
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 16 and Figure 58 for lug nut tightening
and sequence.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
13. Axle - Indicates the maximum weight the axle can sup-
port 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.
3. GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
5. Frame Width - Measurement is from fender to fender
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
16. Application - Indicates which units can be employed
7. Coupler - Type of hitch used on the trailer for towing.
on a particular trailer.
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DCA-150SSJU3 — MAINTENANCE (TRAILER )
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 59) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 59 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 and Table 15 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
Figure 59. Hydraulic Brake Components
star wheel of the adjuster assembly to expand the brake
shoes.
Actuator
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
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.
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.
Periodically check and test the surge “actuator” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
1
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DCA-150SSJU3 — MAINTENANCE (TRAILER)
Tires/Wheels/Lug Nuts
Suspension
Tires and wheels are a very important and critical The leaf suspension springs and associated components
components of the trailer. When specifying or replacing the (Figure 60) should be visually inspected every 6,000 miles
trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and
properly matched.
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
CAUTION - EYESIGHT HAZARD
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRINGTRAILERWHEELS
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.
Figure 60. Major Suspension Components
Table 17. Suspension Torque Requirements
TireWear/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.
Item
Torque (Ft.-Lbs.)
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
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DCA-150SSJU3 — MAINTENANCE (TRAILER)
Lug NutTorque 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 61). DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 61. Wheel Lug Nuts
Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
1
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DCA-150SSJU3 —TRAILERWIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
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DCA-150SSJU3 — GENERATORWIRING DIAGRAM
1
Figure 63. Generator Wiring Diagram
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 65
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DCA-150SSJU3 — ENGINEWIRING DIAGRAM
Figure 64. Engine Wiring Diagram
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DCA-150SSJU3 —TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Defective Exciter Field?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Check for 17.3 ohms across J & K on CN1
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
1
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DCA-150SSJU3 —TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (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.
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in Controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light is
on.
Inspect/repair wire.
Low coolant level?
Fill coolant level.
Low coolant level light is
on. (Optionally Installed)
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Clean/repair radiator grill.
Close doors.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through radiator?
Doors open?
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
High coolant temperture
light is on.
Generator being overloaded?
Thermostat failure?
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
Controller needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
Engine Controller needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust RPM.
Adjust governor actuator.
Adjust governor controller.
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU light(s) or
on.
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DCA-150SSJU3 — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.
QTY. Column
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
The contents and part numbers listed in the parts section are
subject to change without notice. Multiquip does not
guarantee the availibility of the parts listed.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Sample Parts List:
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed to
describe the item can also be shown.
NO. PART NO. PART NAME
QTY. REMARKS
1
2
2
3
4
12345
BOLT ....................... 1.... INCLUDES ITEMS W/
WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY
WASHER, 3/8 IN. .... 1.... MQ-45TONLY
HOSE .................... A/R.. MAKE LOCALLY
BEARING ................ 1.... S/N2345B AND ABOVE
*
*
*
12347
12348
12349
Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial number
range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.
Specific Model Number Use - Indicates that the part is used
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
When ordering a part that has more
than one item number listed, check
the remarks column for help in
determining the proper part to order.
NOTE
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” - Indicates that the part can be
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, orTBD.
“Not Sold Separately” - Indicates that an item cannot be
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
PAGE 70 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — SUGGESTED SPARE PARTS
DCA-150SSJU3WHISPERWATTGENRATOR
W/JOHN DEERE 6068HF285TURBO DIESEL ENGINE
1TO 3 UNITS
Qty.
P/N
Description
1 ......... M3310501403 ..... HOSE, RADIATOR UPPER
1 ......... M3310501503 ..... HOSE, RADIATOR LOWER
1 ......... 0602011062 ........ RADIATOR CAP
1 ......... 0605505070 ........ FUEL CAP
1 ......... 0602015231 ........ V-BELT, FAN
1 ......... 0602122272 ........ UNIT, OIL PRESSURE
1 ......... 0602123263 ........ UNIT, WATER TEMPERATURE
6 ......... 0602042596 ........ FILTER, FUEL PRIMARY
6 ......... 0602042597 ........ FILTER, FUEL FINAL
6 ......... 0602041292 ........ FILTER, OIL CARTRIDGE
3 ......... 0602046684 ........ ELEMENT, AIR
1 ......... 0601870440 ........ CIRCUIT BREAKER 1P 20A
1 ......... 0601870441 ........ CIRCUIT BREAKER 2P 50A
2 ......... LY2DUS12VDC ... RELAY
1 .......... 0601840073 ........ RHEOSTAT
1 .......... 0601840121 ........ KNOB, RHEOSTAT
1 .......... 0602103092 ........ ALARM LAMP
1 .......... 0601810245 ........ BULB, ALARM LAMP
Part number on this Suggested Spare Parts list
may supercede/replace the P/N shown in the text
pages of this book.
NOTE
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 71
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DCA-150SSJU3 — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 72 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3 — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
C0110000112
ROTOR ASSY. .............................. 1 ......... INCLUDES ITEM W/
*
1-1
FIELD ASSY.
FAN
COUPLING DISK
1
1
8
*
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
8131070013
8131611014
8131015003
0012112035
0042612000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0076506312
C0130000603
0845041804
8131315202
8101350013
0012110060
0042610000
0041210000
0010112035
0040012000
0041212000
8131310104
8131312204
8131331003
0017106012
8101333003
0010106030
0040006000
0041206000
M3163400303
0343204220
0043604000
0070506306
0012810030
0012810030
C0131300004
0600815000
0605000013
0030016000
0040016000
*
*
*
*
*
*
*
*
BALANCING PLATE ..................... 1 ......... PURCHASE THE SET OF 1-14
HEX. HEAD BOLT
SPRINGWASHER
SET PLATE, RECTIFIER
RECTIFIER
SURGE ABSORER
INSULATORWASHER
INSULATORWASHER
HEX. HEAD BOLT
SPRINGWASHER
BALANCING WEIGHT KIT
BEARING
10
10
1
2
1
1
1
4
4
1
1
1
2
1
1
4
4
4
6
6
6
1
1
1
10
1
2
2
2
1
8
8
1
1-10
1-11
1-12
1-13
1-14
1-15
2
*
*
*
*
*
*
STARTOR ASSY.
GROMMET
END BRACKET
3
4
5
6
7
8
9
FIELD ASSY., EXCITER
HEX. HEAD BOLT
SPRINGWASHER
PLAIN WASHER
HEX. HEAD BOLT
SPRINGWASHER
PLAIN WASHER
COVER, BEARIG
GASKET, BEARING
COVER, END BRACKET
HEX. HEAD BOLT
COVER, END BASKET
HEX. HEAD BOLT
SPRINGWASHER
PLAIN WASHER
COUPLING RING
HEX. HEAD BOLT
SPRINGWASHER
BEARING
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A
HEX. HEAD BOLT
HEX. HEAD BOLT
COVER, FAN
12
12
1
1
2
2
2
NUT
RUBBER SUSPENSION
HEX. NUT
SPRINGWASHER
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 73
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DCA-150SSJU3— CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 74 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
1-1
1-2
1-3
2
2-1
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
2
1
1
1
6
4
2
4
1
4
1
6
1
1
2
REMARKS
M3213001602
0330000210
0330000240
0330000180
0601808821
0342604120
0021006080
0601823863
0027104016
0601820671
0027105016
0601809666
0027106016
0601820847
0601820848
0027104016
0207004000
M4260600304
0016908020
0602120690
0601831330
0601813977
0601812891
0601812890
0027103010
0030003000
M3260500404
0016906016
0602202592
0030006000
0027106016
LY2DUS12VDC
PTF08A
CONTROL BOX
EDGING
EDGING
EDGING
CIRCUIT BREAKER, 3P 400A
HEX. SOCKET HEAD CAP SCREW
MACHINE SCREW
RELAY UNIT
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR
MACHINE SCREW
CURRENTTRANSFORMER, 300/5A
MACHINE SCREW
OVER CURRENT RELAY
OVER CURRENT RELAY
MACHINE SCREW
HEX. NUT
BRACKET, DIAGNOSTIC GAUGE
HEX. HEAD BOLT
POWER VIEW ............................................. 1 .......... RE521565
DIAGNOSTIC SWITCH
RECEPTACLE
DUST CAP
9
10
11
12
12A
13
14
15
16
17
17A
17B
18
18A
19
20
21
21A
22
23
23A
23B
24
25
26
27
28
29
30
31
31A
31B
32
33
2
1
2
1
1
1
1
2
2
1
4
1
2
2
STRAIN RELIEF
MACHINE SCREW
HEX. NUT
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT
STARTER RELAY
HEX. NUT
MACHINE SCREW
RELAY ......................................................... 1 .......... REPLACES P/N 0601827656
BASE........................................................... 1 .......... REPLACES P/N 0601823109
CLIP............................................................. 2 .......... REPLACES P/N 0601824400
MACHINE SCREW
RECTIFIER
MACHINE SCREW
BRACKET, RESISTOR UNIT
HEX. HEAD BOLT
RESISTOR UNIT
MACHINE SCREW
HOLDER, FUSE
FUSE, 20A
PYCA1
0027104020
0601823240
0027104030
M4260600404
0016906016
M4266600004
0027105016
0601802218
0601806653
0601802149
0027103016
M3213500404
2
2
2
1
2
1
1
1
1
1
2
1
FUSE, 10A
MACHINE SCREW
CONTROL BOX COVER
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 75
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DCA-150SSJU3— CONTROL BOX ASSY. (CONT)
CONTROL BOX ASSY. (CONT.)
PAGE 76 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— CONTROL BOX ASSY. (CONT)
CONTROL BOX ASSY. (CONT.)
NO.
34
35
36
37
37A
38
38A
38B
39
40
41
42
42A
43
44
45
46
47
48
49
50
51
52
52A
53
54
54A
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
PART NO.
PART NAME
QTY.
8
1
1
1
2
4
4
4
6
1
4
17
1
1
1
1
1
REMARKS
0016908020
M3270100304
M3213601904
M3213602004
0330000275
0021005020
0040005000
0207005000
0016906016
M3213602104
0016906016
0016906016
0040506000
M3223001003
0601807641
0601808989
0601801040
0601806859
0601801041
0601840073
0601840121
ECU9988NJD
0021004040
0207004000
0601831340
0602103092
0601810245
0602120096
0602122093
0602123092
0602121081
0602125090
0601810141
0601831330
0601831395
M1223100004
M3223100004
0027105010
0027105010
M9220100004
0080200007
0602122272
0602123263
0602012345
M3246700834
M3357201502
HEX. HEAD BOLT
SELECTOR SWITCH
SWITCH BRACKET
SWITCH BRACKET
EDGING
MACHINE SCREW
SPRINGWASHER
HEX. NUT
HEX. HEAD BOLT
SWITCH COVER
HEX. HEAD BOLT
HEX. HEAD BOLT
TOOTHEDWASHER
CONTROL PANEL
FREQUENCY METER, 45~65HZ 240V
AC AMMETER, O~300A
CHANGE-OVER SWITCH, AMMETER
AC VOLTMETER, O~600V
CHANGE-OVER SWITCH, VOLTMETER
RHEOSTAT (VR), 2W 1K OHM
KNOB
CONTROLLER, ECU ................................... 1 .......... REPLACES P/N 0602202593
MACHINE SCREW
HEX. NUT
SWITCH
ALARM LAMP
1
1
1
1
2
2
1
3
3
1
1
1
1
1
1
1
1
1
1
4
4
2
2
1
1
BULB
TACHOMETER
OIL PRESSURE GAUGE
WATERTEMPERATURE GAUGE
CHARGING AMMETER
FUEL GAUGE
PANEL LIGHT
SWITCH, PANEL LIGHT
SWITCH, ENGINE SPEED
STOPPER
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
UNIT, OIL PRESSURE
UNIT WATERTEMPERTAURE
O-RING ........................................................ 1 .......... 51M7041
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
1
1
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 77
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DCA-150SSJU3— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 78 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
1
1A
1-1
1-2
1-3
2
PART NO.
M3923200084
R521052
RE504836
RE529643
PART NAME
QTY.
REMARKS
ENGINE ....................................................... 1 .......... JOHN DEERE 6068HF285
FAN BELT .................................................... 1 .......... REPLACES P/N 0602011492
CARTRIDGE, OIL FILTER ........................... 1 .......... REPLACES P/N 0602041292
CARTRIDGE, PRIMARY FUEL FILTER ...... 1 .......... REPLACES P/N 0602042596
CARTRIDGE, FINAL FUEL FILTER ............ 1 .......... REPLACES P/N 0602042597
RE522878
0602060010
0602061000
0012110095
0042510000
M3302300404
0010312030
0040012000
0605000011
0030016000
0040016000
M3923200104
0602011062
M4493601304
M9200100904
0150000016
0016908020
M3310501403
M3310501503
0605515148
0605515147
0602015001
M3310201704
0017110020
0016908020
M3310501603
M3310501703
0605515208
0605515215
0605515207
0602046258
0602046684
0602040650
0602040596
0016908020
0207008000
M3373200104
0016908020
M3373100203
0605515197
0602022580
0602022561
BLOWER FAN
1
3
4
5
6
7
8
9
FAN SPACER .............................................. 1 .......... R81911
HEX. HEAD BOLT
SPRINGWASHER
ENGINE FOOT
4
4
2
6
6
2
2
2
1
1
2
1
1
16
1
1
3
1
1
4
8
16
1
1
2
1
1
1
1
1
2
4
4
1
4
1
2
1
1
HEX. HEAD BOLT
SPRINGWASHER
RUBBER SUSPENSION
HEX. NUT
10
11
12
12-1
12-2
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A
30
31
32
33
34
35
36
37
38
39
SPRINGWASHER
RADIATOR
CAP
RUBBER SEAL
PLUG
O-RING
HEX. HEAD BOLT
RADIATOR HOSE, UPPER
RADIATOR HOSE, LOWER
HOSE BAND
HOSE BAND
INTER COOLER
BRACKET, INTER-COOLER
HEX. HEAD BOLT
HEX. HEAD BOLT
COOLER HOSE
COOLER HOSE
HOSE BAND
HOSE BAND
HOSE BAND
AIR CLEANER
ELEMENT, AIR CLEANER
INDICATOR, AIR CLEANER
BAND, AIR CLEANER
HEX. HEAD BOLT
HEX. NUT
BRACKET, AIR CLEANER
HEX. HEAD BOLT
HOSE, AIR CLEANER
HOSE BAND
ADAPTER
90 DEG. ELBOW
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 79
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DCA-150SSJU3— ENGINE AND RADIATOR ASSY. (CONT)
ENGINE AND RADIATOR ASSY. (CONT.)
PAGE 80 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— ENGINE AND RADIATOR ASSY. (CONT)
ENGINE AND RADIATOR ASSY. (CONT.)
NO.
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
61A
61B
62
PART NO.
PART NAME
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HEX. HEAD BOLT
HOSE
HOSE
HOSE
HOSE BAND
BLOWBY HOSE
HOSE BAND
RELAY BRACKET
RELAY ......................................................... 1 .......... AT141011
MACHINE SCREW
HEX. NUT
QTY.
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
2
REMARKS
0603306590
0603300285
0605511395
0603306395
0602021070
0269200640
M9300000203
0602010900
M3316100504
0016908020
0199901050
0193601400
0193600650
0605515106
0191601200
0605515149
M3260600104
0602202592
0027106016
0030006000
0602042601
0010112020
0040012000
0041212000
0040512000
1
2
2
LEAK OFF LINE .......................................... 1 .......... RE67050
HEX. HEAD BOLT
SPRINGWASHER
PLAIN WASHER
1
1
1
1
TOOTHEDWASHER
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 81
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DCA-150SSJU3— OUTPUTTERMINAL ASSY.
OUT
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 82 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
5
REMARKS
M3230700003
M9220100304
M9220100404
0039316000
0040016000
0041416000
0016908035
M3236100703
M3236100104
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
M9220100804
0040006000
0041206000
0080200005
0016906016
M3236400004
M3236300004
0016906020
0601815194
0027104016
0603306775
0027104016
0601870440
0601870441
M1260700504
0222100100
0016906020
0601812598
0601812538
0027104016
0207004000
M3236400204
0016906016
M3236100213
0010112045
0041212000
M9310200004
0030012000
M4236100604
M4236400304
0019206015
TERMINAL BOARD
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX. NUT
SPRINGWASHER
PLAIN WASHER
HEX. HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
HEX. NUT
PLAIN WASHER
MACHINE SCREW
HEX. NUT
SET SCREW
SPRINGWASHER
PLAIN WASHER
RETAINING RING
HEX. HEAD BOLT
CABLE, OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX. HEAD BOLT
TERMINAL BLOCK
MACHINE SCREW
BLIND PLUG
MACHINE SCREW
CIRCUIT BREAKER, SINGLE-POLE 20A
CIRCUIT BREAKER, DOUBLE-POLE 50A 3
BREAKER, FITTING COVER
CUSHION RUBBER
HEX. HEAD BOLT
RECEPTACLE, GFCI 20A
RECEPTACLE, CS6369 50A
MACHINE SCREW
HEX. NUT
10
15
20
5
1
1
2
4
4
4
4
4
2
2
2
2
4
1
9
10
11
11A
11B
12
12A
13
13A
13B
13C
14
15
16
17
18
19
20
21
22
23
24
24-1
25
26
27
28
28A
29
30
31
32
33
34
35
36
37
38
1
6
1
2
2
4
2
1
2
2
2
3
10
10
1
8
1
2
2
2
2
1
1
2
COVER
HEX. HEAD BOLT
TERMINAL COVER
HEX. HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX. NUT
COVER
BRACKET
HEX. HEAD BOLT
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 83
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DCA-150SSJU3— BATTERY ASSY.
BATTERY ASSY.
PAGE 84 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
0602220196
M9310500404
M9103000504
0602220921
M3346900004
M3346901104
BATTERY
1
1
1
2
1
1
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
BATTERY CABLE
BATTERY CABLE
7
8
8A
9
9A
10
10A
CABLE ......................................................... 1 .......... MAKE LOCALLY
0030012000
0040012000
0017112030
0040512000
0017112030
0040512000
HEX. NUT
1
1
1
1
1
1
SPRINGWASHER
HEX. HEAD BOLT
TOOTHEDWASHER
HEX. HEAD BOLT
TOOTHEDWASHER
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 85
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DCA-150SSJU3— MUFFLER ASSY.
MUFFLER ASSY.
PAGE 86 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
MUFFLER
HEX. HEAD BOLT
EXHAUST PIPE
GASKET
HEX. HEAD BOLT
BEND BOLT CLAMP
COVER
QTY.
REMARKS
M3330100502
0016910025
M3333001303
M3333200104
0017110050
0602325066
M3330400804
M3330400903
0016908020
0602326062
1
4
1
1
4
1
1
1
4
1
BRACKET
HEX. HEAD BOLT
U-BOLT SET
9
10
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 87
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DCA-150SSJU3— FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 88 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
1-1
1-2
1-3
1-4
2
3
4
5
6
PART NO.
PART NAME
QTY.
1
1
1
1
5
2
4
2
2
4
1
1
1
2
1
2
REMARKS
M3363001902
0605505070
0605501076
0605516090
0027104015
M3363200204
M9310500104
0016908020
0207308000
0222100150
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
0191302300
0191301800
0605515109
M3483600104
0017112030
FUELTANK
CAP, FUEL TANK
FUEL SENDER UNIT
GASKET
MACHINE SCREW
TANK BAND
SUPPORTER SHEET
HEX. HEAD BOLT
SUPER LOCK NUT
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
7
8
9
O-RING
10
11
12
13
14
15
16
17
HEX. HEAD BOLT
DRAIN HOSE
HOSE BAND
SUCTION HOSE
RETURN HOSE
HOSE BAND
1
1
4
1
CLAMP
HEX. HEAD BOLT
1
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 89
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DCA-150SSJU3— ENCLOSURE ASSY.
R THE PART
NTED PANEL TO
ILLAR YELLOW
OLD
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 90 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
2
3
4
4A
5
6
6A
7
8
PART NO.
PART NAME
QTY.
1
1
2
1
1
6
1
1
16
1
1
1
1
2
4
2
4
2
1
1
8
4
4
1
1
REMARKS
M3413002302
M1413400004
0016908020
M3423002502
M3493111903
0016910030
M3423200304
M3493103104
0019208020
M3310201503
M3493600504
M3310201603
M3493600504
M4310600304
0017112055
M4310200904
0016908020
0016910025
M3310302903
M3310303003
0016908020
0016908020
0207008000
M3310303103
M3310302103
M3310302303
0016908020
M3433001202
M3493200304
0010114040
0030014000
0040014000
0041214000
M3443001702
M3493301504
0016910030
0040510000
M3443301503
M3493305404
M3443301303
M3493305503
0207006000
0019208020
M3443200213
M3443600104
0037906000
BASE
COVER
HEX. HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
SUPPORTER, RADIATOR
ACOUSTIC SHEET
SUPPORTER, RADIATOR
ACOUSTIC SHEET
RUBBER SHEET
HEX. HEAD BOLT
BRACKET, RADIATOR
HEX. HEAD BOLT
HEX. HEAD BOLT
FAN SHROUD
8A
9
9A
10
11
12
13
14
15
16
17
18
18A
19
20
21
22
23
23A
24
24A
24B
24C
25
25A
26
26A
27
27A
28
28A
29
30
31
32
33
FAN SHROUD
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
FAN GUARD
FAN GUARD
FAN GUARD
1
17
1
HEX. HEAD BOLT
CENTER FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
HEX. NUT
SPRINGWASHER
PLAIN WASHER
REAR FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
TOOTHEDWASHER
REAR COVER
ACOUSTIC SHEET
DUCT, REAR COVER
ACOUSTIC SHEET
HEX. NUT
1
12
12
24
24
1
1
4
1
1
1
2
1
13
13
1
1
10
HEX. HEAD BOLT
REAR DOOR
WINDOW PLATE
SELF LOCKING U-NUT
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 91
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DCA-150SSJU3— ENCLOSURE ASSY. (CONT.)
R THE PART
NTED PANEL TO
ILLAR YELLOW
OLD
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 92 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY.(CONT.)
NO.
33A
34
35
35A
36
36A
37
38
39
39A
40
40A
41
42
43
44
45
45A
46
46A
46B
47
48
48A
49
49A
50
50A
51
51A
52
52A
53
53A
54
54A
55
55A
56
57
57A
58
58A
59
PART NO.
PART NAME
QTY.
10
1
4
4
2
2
3
2
1
1
1
1
1
39
1
4
1
1
4
4
4
2
1
1
1
1
1
1
1
1
2
2
1
REMARKS
0041206000
PLAIN WASHER
DOOR HANDLE
MACHINE SCREW
HEX. NUT
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0019208020
M9310000004
M3463101303
M3493507403
M3463201702
M3493508203
M3423202203
0019208020
M3310600004
0019208020
M3453201402
M3493405514
0019108055
HINGE
WASHER
HEX. HEAD BOLT
BLIND PLUG
ROOF PANEL
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
OVER COVER, FRONT FRAME
HEX. HEAD BOLT
COVER
HEX. HEAD BOLT
SPLASHER PANEL
ACOUSTIC SHEET
HEX. HEAD BOLT
SPRINGWASHER
PLAIN WASHER
HEX. HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX. NUT
DOOR HANDLE
SEAL RUBBER
MACHINE SCREW
HEX. NUT
MANUAL PAK
MACHINE SCREW
GUTTER
0042308000
0042408000
0016910025
M3453004603
M3493422103
M3453004703
M3493421103
M3453004103
M3493421304
M3453004803
M3493424903
M3453302703
M3493421004
M3453302803
M3493421004
M3453302903
M3493423904
M3453303003
M3493424404
0207006000
M9113000002
C9312500004
0021806016
0030006000
0600800320
0021806016
M3453700404
1
1
1
1
1
29
4
4
16
16
1
4
1
60
61
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 93
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DCA-150SSJU3— ENCLOSURE ASSY. (CONT.)
R THE PART
NTED PANEL TO
ILLAR YELLOW
OLD
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 94 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY.(CONT.)
NO.
62
63
63A
64
64A
65
66
67
68
69
PART NO.
PART NAME
HEX. HEAD BOLT
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
STOPPER
MACHINE SCREW
BLIND PLUG
HEX. HEAD BOLT
TOOTHEDWASHER
QTY.
REMARKS
0019206015
M9110100204
M9116100004
M9110100304
M9116100004
0019208020
0601850097
0027208025
M9310000004
0016908020
0040508000
4
4
4
4
4
9
8
8
8
1
1
69A
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 95
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DCA-150SSJU3— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 96 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
4
4
3
3
4
1
1
1
2
1
1
1
1
1
1
1
REMARKS
0229201200
0228901005
0228901090
0228901150
0228900885
0228900520
0228900580
0229201140
0228801070
0228800640
0228800680
0228100665
0228100370
0228100300
0228100365
0228100280
0228100070
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
9
10
11
12
13
14
15
16
17
1
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 97
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DCA-150SSJU3— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
PAGE 98 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO.
1-1
1-2
1-3
PART NO.
PART NAME
QTY.
REMARKS
M3550003003
M9520100304
M9520100603
DECAL; OPERATING PROCEDURES ....................1........ M35000300
DECAL; SAFETY INSTRUCTIONS .........................1........ M92010030
DECAL;CAUTION ...................................................2........ M92010060
CONTROL PANEL & BOX GROUP
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
M3550002803
M3550002903
M9520000104
M9520000204
M9520000904
M9520100004
M9520100204
M9520200404
DECAL;CONTROL PANEL......................................1........ M35000280
DECAL; OPERATING PANEL ..................................1........ M35000290
PLATE; AMMETER CHANGE-OVER SWITCH........1........ M92000010
PLAYE; VOLTMETER CHANGE-OVER SWITCH ....1........ M92000020
DECAL; DIAGNOSTIC SWITCH ..............................1........ M92000090
DECAL;WARNING ELECTRIC SHOCK HAZARD ...1........ M92010000
DECAL;CAUTION ...................................................1........ M92010020
DECAL; OVER CURRENT RELAY ..........................1........ M92020040
ENGINE & RADIATOR GROUP
3-1
3-2
3-3
3-4
3-5
3-6
M9500000004
M9500100004
M9503000004
M9503000103
M9530100004
M9510100004
DECAL; OIL DRAIN PLUG ......................................1........ M90000000
DECAL;WATER .......................................................1........ M90010000
DECAL;WARNING MOVING PARTS.......................2........ M90300000
DECAL;WATER *OIL CHECK..................................1........ M90300010
DECAL;WARNING HOT COOLANT ........................1........ M90310000
DECAL; CAUTION HOT PARTS...............................1........ M91010000
OUTPUTTERMINAL GROUP
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
M1550000204
M1550002203
M3550000804
M9520000004
M9520000504
M9520100004
M9520100404
M9520100503
M9520200003
DECAL;NOTE .........................................................1........ M15000020
DECAL; RECEPTACLE & CIRCUIT BREAKER.......1........ M15000220
DECAL;NOTE .........................................................1........ M35000080
DECAL; GROUND....................................................1........ M92000000
DECAL; START CONTACT ......................................1........ M92000050
DECAL;WARNING ELECTRIC SHOCK HAZARD ...1........ M92010000
DECAL; DANGER HIGH VOLTAGE..........................1........ M92010040
DECAL;WARNING ..................................................1........ M92010050
DECAL; OUTPUT TERMINAL..................................1........ M92020000
BATTERY GROUP
5-1
5-2
5-3
M9500300004
M9500300104
M9510100403
DECAL; - ..................................................................1........ M90030000
DECAL; +.................................................................1........ M90030010
DECAL;CAUTION ...................................................1........ M91010040
MUFFLER GROUP
6-1
M9503200004
DECAL;WARNING ENGINE EXHAUST ..................1........ M90320000
FUELTANK GROUP
7-1
7-2
M9500500004
M9500500104
DECAL; DIESEL FUEL ............................................1........ M90050000
DECAL; FUEL DRAIN PLUG ...................................1........ M90050010
BONNET GROUP
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 99
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DCA-150SSJU3— NAMEPLATE AND DECALS ASSY. (CONT.)
NAMEPLATE AND DECALS ASSY. (CONT.)
PAGE 100 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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DCA-150SSJU3— NAMEPLATE AND DECALS ASSY. (CONT.)
NAMEPLATE AND DECALS ASSY. (CONT.)
NO.
8-1
8-2
PART NO.
M9510200002
0600500090
PART NAME
QTY.
REMARKS
DECAL; MQ .............................................................1........ M91020000
EMBLEM
MACHINE SCREW
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
1
2
1
2
1
1
2
1
4
1
0021106016
8-3
8-4
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-12
M3560100903
M3560101003
M3560103104
M3560103403
M3560101304
M3560103303
M3560101504
M3560103204
M3550002204
M9510000104
STRIPE
DECAL;CAUTION ...................................................1........ M35000220
DECAL; DOCUMENT BOX LOCATED .....................1........ M91000010
1
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 101
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Effective: February 22, 2006
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon- Multiquipreservestherighttoquoteandsell
dition,intheoriginalMultiquippackage(if directtoGovernmentagencies,andtoOriginal
any), and with Multiquip part numbers Equipment Manufacturer accounts who use
Terms of payment for parts are net 30 days.
FREIGHTPOLICY
clearlymarked.
our products as integral parts of their own
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
SPECIALEXPEDITINGSERVICE
a. Obsolete parts. (If an item is in the
price book and shows as being re- A$35.00surchargewillbeaddedtotheinvoice
placedbyanotheritem,itisobsolete.) forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
(such as gaskets, seals, “O” rings,
b. Any parts with a limited shelf life
andotherrubberparts)thatwerepur- LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
chasedmorethansixmonthspriorto
thereturndate.
Multiquip shall not be liable hereunder for
damagesinexcessofthepurchasepriceofthe
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
c. Anylineitemwithanextendeddealer item with respect to which damages are
netpriceoflessthan$5.00.
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
otherspecial,consequentialorincidentaldam-
ages.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnorauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Suchmaterialwillbeheldforfiveworking
days from notification, pending instruc-
tions.Ifareplyisnotreceivedwithinfive
days,thematerialwillbereturnedtothe
senderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
datewillbebilledattherevisedprice.Rebates
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All forpricedeclinesandaddedchargesforprice
partsmustbereturnedfreightprepaidto increaseswillnotbemadeforstockonhand
Multiquip’sdesignatedreceivingpoint.
atthetimeofanypricechange.
PAGE 102 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)
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NOTE PAGE
DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07) — PAGE 103
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
Internet:www.mqpower.com
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
Manufactured for Multiquip Inc.
by
DENYO CO., LTD, JAPAN
Your Local Dealer is:
MQPOWER
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
Internet:www.mqpower.com
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