PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
ULTRA-SILENTTM SERIES
MODEL DCA-85USJ
GENERATOR
PARTS LIST NO. M2870400004
Revision #0 (09/17/04)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
Download from Www.Somanuals.com. All Manuals Search And Download.
PAGE 2 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
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
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 2004, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used,
reproduced, or altered without written permission.All other trademarks are the property of thier respective owners and used with
permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and
should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the DCA-85USJ Ultra Silent Generator.Multiquip Inc.reserves the right to discontinue or change specifications, design or
the information published in this publication at any time without notice and without incurring any obligations.
To find the latest revision of this
publication, visit our website at:
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 3
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
MQ POWER DCA-85USJ
COMPONENT DRAWINGS
ULTRA-SILENT GENERATOR
Explanation of Code in Remarks Column ....................... 54
Suggested Spare Parts .................................................. 55
Generator Assembly.................................................. 56-57
Control Box Assembly............................................... 58-61
Engine & Radiator Assembly..................................... 62-65
Output Terminal Assembly......................................... 66-67
Battery Assembly ...................................................... 68-69
Muffler Assembly ...................................................... 70-71
Fuel Tank Assembly .................................................. 72-73
Enclosure #1 Assembly ............................................ 74-77
Enclosure #2 Assembly ............................................ 78-81
Rubber Seals Assembly ............................................ 82-83
Nameplate and Decals .............................................. 84-87
California Proposition 65Warning .....................................2
Here's How To Get Help ....................................................3
Table Of Contents .............................................................4
Parts Ordering Procedures ...............................................5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) ........................................... 7
Safety Message Alert Symbols ....................................8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 20
Engine Operating Panel ............................................. 22-23
OutputTerminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
OutputTerminal Panel Connections ........................... 30-31
Pre Setup .................................................................. 32-35
Generator Start-up Procedure (Manual) ..................... 36-38
Generator Start-up Procedure (Auto Mode) .................... 39
Generator Shut-Down Procedure .................................... 40
Maintenance .............................................................. 41-43
Trailer Maintenance.................................................... 44-47
TrailerWiring Diagram ..................................................... 48
GeneratorWiring Diagram ............................................... 49
EngineWiring Diagram ................................................... 50
GeneratorTroubleshooting .............................................. 51
Engine ControllerTroubleshooting ................................... 52
Terms and Condition of Sale — Parts ............................ 88
Specification and part
number are subject to
NOTE
change without notice.
PAGE 4 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
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]
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
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 5
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA-85USJ
Revolving field, self ventilated, open protected type synchronous
generator
Armature Connection
Phase
Star with Neutral
3
Zig Zag
Single
Standby Output
Prime Output
Voltage
90.2 KVA (72.2 KW)
82 KVA (65.6 KW)
240V or 480V
66 KW
60KW
240/120V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1
Single Phase, 60 Hz
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
Type
JOHN DEERE 4045TF 275
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
4.19 in. x 5 in. (106 mm x 127 mm)
102HP/1800 rpm
275 cu. in. (4,500 cc)
Electric 12VDC
Coolant Capacity
Lube Oil Capacity
Fuel Type
3.7 gal. (14 liters) plus 2 quarts in retaining tank
3.5 gal. (13.2 liters)
#2 Diesel Fuel
Fuel Tank Capacity
127 gal. (480 liters)
5.5 gal. (20.8L)/hr at full load
2.6 gal. (10.0L)/hr at 1/2 load
3.8 gal. (14.5L)/hr at 3/4 load
1.8 gal. (6.9L)/hr at 1/4 load
Fuel Consumption
Battery
12V BCI Group 27
PAGE 6 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 7
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA85USJ — 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-85USJ
ULTRA-SILENT™ 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA85USJ — 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 Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump 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.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 9
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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-85USJ 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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 5.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
is being transfer to a load.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 11
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 13
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR DECALS
The DCA-85USJ 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 15
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 16 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 17
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERAL INFORMATION
Open Delta Excitation System
DCA-85USJ Series Familiarization
Generator
The DCA-85USJ generator is equipped with the state of the
art "Open-Delta" excitation system.The open delta system
The MQ Power Model DCA-85USJ is a 65.6 kW generator
(Figure 5) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other industrial
and construction machinery.
consist of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■
■
■
■
■
■
■
■
■
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Pre-heat Lamp
Panel Light/Panel Light Switch
Auto ON/OFF Engine Controller (MPEC)
Fuel Leak Detected Alarm Lamp
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C.This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Generator Control Panel
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.
The “Generator Control Panel”is provided with the following:
■
■
■
■
■
■
■
■
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 250 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Engine
The DCA-85USJ is powered by a 4 cycle, water cooled,
direct injection, turbocharged John Deere Model 4045TF275
Diesel Engine. This engine is designed to meet every
performance requirement for the generator.ReferenceTable
1 for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
■
■
■
■
■
■
■
Automatic Voltage Regulator
CurrentTransformer
Over-Current Relay
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
Voltage Selector Switch
Electric Governor System
The electric governor system controls the RPMs of the
engine. When the engine demand increases or decreases,
the governor system regulates the frequency variation to
.25%.
OutputTerminal Panel
Extension Cables
The “Output Terminal Panel” is provided with the following:
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 5) as a guide
for selecting proper extension cable size.
■
■
■
■
■
■
■
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)
PAGE 18 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MAJOR COMPONENTS
Table 3. Generator Major Components
ITEM NO.
DESCRIPTION
Muffler Assembly
1
2
3
4
5
6
7
8
9
Engine Assembly
Enclosure Assembly
Generator Assembly
Output Terminal Assembly
Fuel Tank Assembly
Battery Assembly
Generator Control Panel Assembly
Engine Operating Panel Assembly
Figure 5. Major Components
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 19
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
PAGE 20 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR CONTROL PANEL
Figure 6. 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-85USJ Generator Control Panel (Figure 6).
1. Main Circuit Breaker – This three-pole, 250A main
breaker is provided to protect the the U,V,andW Output
Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
2. Frequency Meter – Indicates the output frequency in
■
■
■
■
■
Over-Current Relay
Voltage Rectifer (AVR)
Starter Relay
CurrentTransformer
Voltage Selector Switch
hertz (Hz). Normally 60 Hz.
3. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
4. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
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 60 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. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 21
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
PAGE 22 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of During cranking cycle ,The MPEC will attempt to crank the
the DCA-85USJ Engine Operating Panel (Figure 7).
engine for 10 seconds before disengaging. If the engine does
not engage (start) by the third attempt, the engine will be
shutdown by the engine controller’s Over Crank Protection
mode. If the engine engages at a speed (RPM's) that is not
safe, the controller will shutdown the engine by initializing
the Over Speed Protection mode.
1. Panel Light – Normally used in dark areas or at night
time.When activated, panel lights will illuminate.When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
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.
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. When
starting the generator the oil pressure may read a little
higher, but after the engine warms up the oil pressure
should return to the correct pressure range.
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.
4. WaterTemperature Gauge – During normal operation
this gauge be should read between 180° and 221°F.
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the AUTO position. In this position the
generator will monitor the AC line output from the
building's power source.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
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.
8. Pre-Heat Lamp – As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine.
When the lamp turns off, the engine has been preheated
and will start automatically.
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.
9. Fuel Leak Detected Alarm Lamp – This lamp will
illuminate when a leak in the fuel tank containment
enclosure is detected.
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.
10. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical
row of status LED's (inset), that
when lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has
been detected the engine
controller will evaluate the fault
and all major faults will
shutdown the generator.
E. Overspeed Shutdown – Indicates the engine is running
at an unsafe speed.This is considered a major fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 23
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 8) 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) 120V 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 8. OutputTerminal Panel
PAGE 24 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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 11) 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 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11.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 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 10) provided on the output
terminal panel.These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 12. Plastic Face Plate (OutputTerminal Lugs)
Figure 10. 120/240VTwist-Lock
Auxiliary Receptacles
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 25
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Blower Fan
Loads can be connected to the generator by the OuputTerminal
Lugs or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
This unit has an intake fan located at the rear of the machine
to draw outside air into the cabinet to cool the engine. The
fan has a 10 amp AC fuse located beneath the Voltage
Selector Switch (Figure 15).
To protect the output terminals from overload, a
3-pole, 250A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Figure 15. Blower Fan Fuse
DANGER - ELECTROCUTION HAZARDS
This fuse has current running through it any time the engine
is running.This fuse is NOT connected to the main circuit
breaker of the generator. Attempting to replace the fuse
with the engine and/or generator operating
could result in electrocution and severe
bodily harm. ALWAYS turn the unit
completely off before attempting to replace
or handle this fuse.
Figure 13. Connecting Loads
Over Current Relay
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Figure 14. Over Current Relay
PAGE 26 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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 4 below
when connecting loads.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 5.
Table 4. 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
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
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
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 5. 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 120
Volts
At 240
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
1200
1800
2400
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.
50 ft.
CAUTION: Equipment damage can result from low voltage.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 27
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 16) is located above Table 7 describes the generator’s current output capability
the output terminal panel’s Hard Wire Hook-up Panel. It for both 1Ø-phase and 3Ø phase applications.
has been provided for ease of voltage selection.
Table 7. Generator Ampere Ratings
DCA-8USJ
Single Phase
Three Phase*
kW
kVA
N/A
82
120V
250A x 2
N/A
208V
240V
250A
197A
480V
N/A
60
N/A
65.6
228A
99A
* Power Factor = 0.8
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the output termi-
nals or the 3 twist lock auxilliary receptacles.
Tables 8 and 9 show what amount of current is available at
the GFCI receptacles when the output terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep-
tacles.
Figure 16. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
Table 8. 1
Ø
GFCI Receptacle Load Capability
KW in Use
Available Load
Twist-Lock (CS6369)
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
1Ø 240/120V
CAUTION - CHANGINGVOLTAGES
60
0
58.8
57.6
56.4
55.2
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
NEVER change the position of the voltage selector switch
while the engine is running.ALWAYS place circuit breaker
in the open position before selecting voltage.
Table 9. 3 GFCI Receptacle Load Capability
Ø
Generator OutputVoltages
KVA in Use
Available Load
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
(UVWO Terminals)
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
3Ø 240/480V
82
78
74
70
65
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 6. Voltages Available
Three Phase
208V
220V
240V
416V
440V
254V
480V
277V
(Switchable)
Single Phase
(Switchable)
120V
127V
139V
240V
PAGE 28 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GAUGE READING
How to Read the OutputTerminal Gauges.
Reading Amperage
The gauges and selector switches on the control panel To determine the amperage at a terminal lug, set the
DO NOT effect the generator output. They are provided to AC Ammeter Change-Over Switch to the appropriate
help observe how much power is being supplied at the setting (Figure 20) to activate the AC Ammeter Gauge
Output terminals lugs.
(Figure 21) and read the available amperage at the terminal
lug.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 17) to the position which produces For example, to measure the amperage at the U
the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the volt-
terminal lug, set the AC Ammeter Change-Over Switch to
U and read the AC Ammeter Gauge.
age selector switch.)
Figure 17. Voltage
Selector Switch 240/
139VThree Phase
Position
Figure 21. AC Ammeter
(Amp reading on U lug)
Figure 20. AC Ammeter
Change-Over Switch
For 3Ø 208V/1Ø,120V, place
NOTE
the Voltage Selector Switch
in the 3 Phase 340/139
position.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
Reading Voltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 18) to activate the AC Voltmeter Gauge
(Figure 19) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the ACVoltmeter Gauge.
Figure 18. AC Voltmeter
Change-Over Switch
Figure 19. ACVoltmeter Gauge
(Volt reading on W-U Lug)
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 29
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — OUTPUT TERMINAL PANEL CONNECTIONS
UVWOTerminal Output Voltages
3Ø 208V/1Ø120V OutputTerminal 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-208 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.
3Ø 240/139 OutputTerminal LugVoltages
Figure 25. Voltage Selector
Switch 3Ø-208V/1Ø-120V
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 22.
Figure 26. OutputTerminal Lugs
3Ø-208V/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. OutputTerminal Lugs
240/139VThree Phase 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)
PAGE 30 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal Lug Voltages
1Ø 240V/120V OutputTerminal 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 28.
shown in Figure 30.
Figure 28. UVWOTerminal Lugs
480/277VThree Phase Connections
Figure 30. UVWOTerminal Lugs
1Ø-240V/120V Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 31
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — PRE-SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 250 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 31) on the dipstick. See Table 10 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.
The generator unit has an internal fuel tank located at the
bottom of the cabinet (Figure 32). ALWAYS fill the fuel tank
with clean and fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 31. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the John Deere Engine Owner's Manual. Oil should be
warm before draining.
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
Table 10. Recommended Motor Oil
OIL: SAE
F
C
122
104
86
50
40
30
20
10
0
68
50
32
-14
-4
-10
-20
-30
-40
Figure 32. Internal FuelTank System
-22
-40
PAGE 32 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — PRE-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 34).
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 33).
CAUTION - 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 34. Fueling the Generator
3. NEVER overfill fuel tank – It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait for
fuel to rise in filler neck (Figure 35).
Figure 33. Only Fill on Level Ground
NOTE
ONLY! use #2 diesel fuel when
refueling.
Figure 35. Full Fuel Tank
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 36).
Figure 36. Fuel Expansion
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 33
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — PRE-SETUP
Coolant (John Deere Antifreeze/Summer Coolant/Water)
Cleaning the Radiator
John Deere recommends John Deere Antifreeze/Summer
Coolant for use in thier engines, which can be purchased in
concentrate (and mixed with 50% demineralized water) or
pre-diluted. See the John Deere Engine Owner's Manual
for further details.
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
negative battery terminal disconnected.
Air Cleaner
WARNING - BURN HAZARDS
Periodic cleaning/replacement is necessary. Inspect it in
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.
accordance with the John Deere Engine Owner's Manual.
Fan BeltTension
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 11 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 37) when depressed with the thumb as shown
below.
Table 11. Coolant Capacity
Engine and Radiator
Reserve Tank
3.7 Gal. (14 liters)
2 Quarts (1.9 liters)
Figure 37. Fan BeltTension
CAUTION - ROTATING PARTS
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.
NEVER place hands near
the belts or fan while the
generator set is running.
Table 12. 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
PAGE 34 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — PRE-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 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. The battery type used in this
generator is BCI Group 27.
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
incorrectly, electrical damage to the
NOTE
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.
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.
CAUTION - BATTERY SERVICING SAFETY
Battery Cable Installation
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ALWAYS be sure the battery cables (Figure 38) are properly
connected to the battery terminals as shown below.The Red
Cable is connected to the positive terminal of the battery,
and the Black Cable is connected to the negative terminal
of the battery.
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
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
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 38. Battery Connections
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 35
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)
Before Starting
4. Close all engine enclosure doors (Figure 40).
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING - STARTINGTHE GENERATOR
Figure 40. Engine Enclosure Doors
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
1. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 39) in the OFF position prior to starting the engine.
5. Place the voltage selector switch
in the desired voltage position
(Figure 41).
Figure 41. Voltage
Selector Switch
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Connect the load to the receptacles or the Output
Terminal Lugs as shown in Figure 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
3. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
PAGE 36 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)
Starting (Manual)
9. The generator's frequency meter (Figure 45) should be
displaying the 60 cycle output frequency in HERTZ.
8. Place the MPEC Control Switch in the MANUAL
position to start the engine (Figure 42).
Figure 45. Frequency Meter (Hz)
Figure 42. MPEC Control Switch
(Manual Position)
10. The generator's AC-voltmeter (Figure 46) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 47) to increase or decrease the
desired voltage.
In cold weather conditions, placing the MPEC Control
Switch in the MANUAL position will preheat and start
the engine AUTOMATICALLY. The Preheat Lamp
(Figure 43) will turn off when the engine has started.
7. Once the engine starts, let the engine run for 1-2 minutes.
Listen for any abnormal noises.
Figure 46.Voltmeter
Figure 43. Pre-Heat Lamp
8. Verify that the Engine Running
status LED on the MPEC unit
(Figure 44) is ON (lit) after the
engine has been started.
Figure 47.Voltage Adjust Control Knob
11. The ammeter (Figure 48) will
indicate zero amps with no load
applied.When a load is applied, the
ammeter will indicate the amount
of current that the load is drawing
from the generator.
Figure 44. Engine
Running LED (ON)
Figure 48. Ammeter (No Load)
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 37
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)
15. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 52).
12. The engine oil pressure gauge
(Figure 49) will indicate the oil
pressure (kg/ cm2) of the engine.
Under normal operating conditions
the oil pressure is approximately
35~65 PSI.
Figure 49. Oil Pressure Gauge
13. The coolant temperature gauge (Figure 50) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
Figure 52. Main, Aux. and GFCI
Circuit Breakers (ON)
16. Observe the generator's ammeter (Figure 53) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if a load is in use.
Figure 50. CoolantTemperature Gauge
14. The tachometer gauge (Figure 51) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 53. Ammeter (Load)
17. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 51. EngineTachometer Gauge
PAGE 38 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)
Starting (Auto Mode)
1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.
DANGER - ELECTRICAL SYSTEM HAZARDS
2. Place the MPEC Control Switch (Figure 54) in the AUTO
position .
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.
Figure 54. MPEC Control Switch (AUTO)
3. Continue to follow the steps outlined in the Manual Start-
up procedure (start at step 9).
CAUTION - BACKUP GENERATOR USE
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
When the generator is set in the
AUTO mode, the generator will
automically start in the event of
comercial power falling below a
NOTE
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
WARNING - AUTO MODE MAINTENANCE
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 39
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
WARNING - SHUTTING DOWNTHE GENERATOR
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 39) circuit
breakers to OFF position.
NEVER stop the engine suddenly except in an emergency.
DO NOT use the emergency stop switch a as method of
shutting down the generator. This switch is ONLY to be
used in the event of an emergency.
2. Place the MPEC Control Switch switch (Figure 55) to
the OFF/RESET position.
Shutdown Procedure
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 39 to the OFF position.
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Place the MPEC Control Switch (Figure 55) to the
OFF/RESET position.
Figure 55. MPEC Control Switch (Off/Reset)
5. Verify that the all status LED on the MPEC display
are OFF (not lit).
6. Remove all loads from the generator.
PAGE 40 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 13. 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.
General Inspection
Service Daily
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.
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.
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
Air Cleaner with Dust Indicator
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.
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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 41
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MAINTENANCE
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.
Check Oil Level
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 the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level.The oil level
must be between the two notches on the dipstick as shown
in Figure 33.
■
■
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufaturer.
Replacing Oil Filter
■
■
■
■
Remove the old oil filter.
■
Close radiator cap tightly.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
WARNING - BURN HAZARDS
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.
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
Replacing Fuel Filter
■
Replace the fuel filter cartridge with new one every 500
hours or so.
Generator Storage
For longe term storage of the generator the following is
recommended:
■
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.
■
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
■
Vent any air.
■
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
■
■
■
■
■
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
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.
PAGE 42 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MAINTENANCE
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 56). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 5).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.
Figure 56. DCA-45SIU2 Battery Charger &
JacketWater Heater Power Connections
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 43
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TRAILER MAINTENANCE
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-85USJ
Ultra-Silent Generator.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 17 and Figure 59 for lug nut tightening
and sequence.
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.
PAGE 44 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TRAILER MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 57) 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 57 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
Figure 57. 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 14. 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
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 45
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TRAILER MAINTENANCE
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 58) 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 16.
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 58. Major Suspension Components
Table 16. 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 15 (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.
TABLE 15. TIRE WEARTROUBLESHOOTING
SHACKLE BOLT
SOLUTION
CAUSE
WEAR PATTERN
SPRING EYE BOLT
Adjust pressure to
particular load per tire
manufacturer.
Over Inflation.
Center Wear
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.
Under Inflation.
Edge Wear
Side Wear
Loss of camber
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup &
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Flat Spots
PAGE 46 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TRAILER MAINTENANCE
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 59). DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 17.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 17. 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 59. Wheel Lug Nuts
Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 47
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TRAILERWIRING DIAGRAM
Figure 60.Trailer/Towing Vehicle Wiring Diagram
PAGE 48 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATORWIRING DIAGRAM
Figure 61. GeneratorWiring Diagram
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 49
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINEWIRING DIAGRAM
PAGE 50 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 18 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.
TABLE 18. 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
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 51
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ —TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor
Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
TABLE 19. 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.
PAGE 52 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 53
Download from Www.Somanuals.com. All Manuals Search And Download.
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #, +,
*
%, or <, belong to the same assembly or kit.
If more than one of the same
reference number is listed, the
last one listed indicates newest
(or latest) part available.
The contents of this catalog are
subject to change without
notice.
PAGE 54 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — SUGGESTED SPARE PARTS
DCA-85USJ ULTRA-SILENT GENRATOR
W/JOHN DEERE 4045TF275 DIESEL ENGINE
1TO 3 UNITS
Qty.
P/N
Description
5 ......... 0602041292 ........ FILTER, OIL
5 ......... 0602042594 ........ FILTER, FUEL, PRIMARY
5 ......... 0602042595 ........ FILTER, FUEL, FINAL
3 ......... 0602046377 ........ ELEMENT, AIR
1 ......... 0602011493 ........ BELT, FAN
1 ......... 0605505070 ........ CAP. FUEL TANK
1 ......... 0602122272 ........ UNIT, OIL PRESSURE
1 ......... 0602123261 ........ UNIT, WATER TEMPERATURE
2 ......... 0601802149 ........ FUSE, 10A
1 ......... 0602123282 ........ SENDER, WATER SWITCH (ENGINE SIDE)
1 ......... 0602122281 ........ SENDER, OIL SWITCH (ENGINE SIDE)
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-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 55
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR ASSY.
GENER
PAGE 56 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
B6110000102
ROTOR ASSY............................................ 1 .......... INCLUDES ITEMS W/
*
1-1
FIELD ASSY.
FAN
HEX, HEAD BOLT
COUPLING DISK
1
1
8
5
*
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
8101070033
0012810035
8101611004
*
*
*
*
*
*
*
*
BALANCING PLATE.................................. 1 .......... MUST PURCHASE ROTOR ASSY.
HEX, HEAD BOLT
SPRINGWASHER
SET PLATE, RECTIFIER .......................... 1 .......... MUST PURCHASE ROTOR ASSY.
RECTIFIER ............................................... 2 .......... PT3610
SURGE ABSORBER ................................ 1 .......... ERZ-M14JK621A
INSULATORWASHER
INSULATORWASHER
HEX, HEAD BOLT
SPRINGWASHER
BALANCING WEIGHT KIT
0012110030
0042510000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906311
M2163400003
0343204170
0043604000
B6130000303
0845041804
8101315202
8101350013
0012110070
0042610000
0041210000
0017110035
8101310014
8131312014
0017106012
8101331003
0017106012
8101333003
0340406040
0041206000
0012810030
8111332014
0340406040
0041206000
0600815000
0605000010
0030012000
0040012000
0041212000
0070506306
8
8
1-10
1-11
1-12
1-13
1-14
1-15
1-16
2
*
*
*
*
*
*
*
1
1
4
4
1
BEARING .................................................. 1 .......... 6311DDUC3
COUPLING RING
HEX, HEAD BOLT
SPRINGWASHER
STATOR ASSY. ......................................... 1 .......... B6134000304
GROMMET
1
8
8
3
4
5
6
7
8
9
2
1
END BRACKET
FIELD ASSY. EXCITER ............................ 1 .......... B6134000304
HEX, HEAD BOLT
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
COVER, BEARING
GASKET, BEARING
HEX, HEAD BOLT
COVER, END BRACKET
HEX, HEAD BOLT
COVER, END BRACKET
HEX, HEAD BOLT
PLAIN WASHER
HEX, HEAD BOLT
COVER, FAN
HEX, HEAD BOLT
PLAIN WASHER
NUT
RUBBER SUSPENSION
HEX, NUT
SPRINGWASHER
PLAIN WASHER
BEARING .................................................. 1 .......... 6306ZZ
4
4
4
6
1
1
6
1
4
1
1
1
12
1
1
1
1
2
2
2
2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
27A
27B
28
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 57
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 58 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
CONTROL BOX
EDGING
QTY.
1
2
REMARKS
M2213000502
0330000180
0601808822
0021005080
0601823863
0027104016
0601820671
0027105016
0601806118
0027106016
0601820845
0601820846
0027104016
0207004000
M3213500013
0016906016
M3270100104
CIRCUIT BREAKER ........................................ 1 ............ KAF3625010393P 250A
MACHINE SCREW
RELAY UNIT .................................................... 2 ............ MSA9013A
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR .............. 1 ............ NTA-5A-2DB
MACHINE SCREW
CURRENTTRANSFORMER ........................... 3 ............ 814-943 200/5A
MACHINE SCREW
OVER CURRENT RELAY ................................ 1 ............ LR2D1308
OVER CURRENT RELAY ................................ 1 ............ LA7D1064
MACHINE SCREW
HEX, NUT
4
4
4
9
10
11
12
13
13A
14
15
16
6
2
2
1
4
CONTROL BOX COVER
HEX, HEAD BOLT
SELECTOR SWITCH ...................................... 1 ............ XUSS01574
........................................................................................ INCLUDES ITEMS W/
*
16A
17
18
19
20
21
22
23
24
24A
25
26
27
28
29
30
31
32
33
34
35
35A
TBD
KNOB, SELECTOR SWITCH
SPACER
SWITCH BRACKET
EDGING
1
8
1
*
M3276600004
M3213600503
0330000330
0027104016
0016906016
M3213600604
0016906016
0016906016
0040506000
M2223000403
0601807641
0601808988
0601801040
0601806849
0601801041
0601840073
0601840121
0602202593
0601831340
0027104035
0207004000
2
MACHINE SCREW
HEX, HEAD BOLT
SWITCH COVER
HEX, HEAD BOLT
HEX, HEAD BOLT
TOOTHEDWASHER
CONTROL PANEL
4
6
1
4
10
1
1
FREQUENCY METER .................................... 1 ............ FCF-6 45~65Hz 240V
AC AMMETER ................................................ 1 ............ ACF-6 0~200A/400A:5A
CHANGE-OVER SWITCH, AMMETER ........... 1 ............ SL-2AS
AC VOLTMETER ............................................. 1 ............ SCF-6 0~600V
CHANGE-OVER SWITCH,VOLTMETER ........ 1 ............ SL-2VS
RHEOSTAT (VOLTAGE REGULATOR) ............. 1 ............ RA20A2SE102BJ 2W 1k OHM
KNOB .............................................................. 1 ............ 25N
CONTROLLER ................................................ 1 ............ ECU(CAN)
SWITCH .......................................................... 1 ............ 7562K4
MACHINE SCREW
HEX, NUT
2
2
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 59
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 60 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
PART NO.
PART NAME
PREHEAT LAMP ............................................. 1 ............ PL-05
BULB
TACHOMETER ................................................ 1 ............ 111812
OIL PRESSURE GAUGE ................................ 1 ............ 100174
WATER TEMPERATURE GAUGE ................... 1 ............ 100182
CHARGING AMMETER .................................. 1 ............ 100158
FUEL GAUGE.................................................. 1 ............ 100176
PANEL LIGHT.................................................. 1 ............ 98268-00370
SWITCH, PANEL LIGHT ................................. 1 ............ 90-0001
QTY.
REMARKS
36
0602103092
0601810245
0602120096
0602122093
0602123092
0602121080
0602125090
0601810141
0601831330
M1223100004
M3223100004
0027105010
0027105010
M9220100004
0080200007
0602202592
0027106016
LY-2D DC12V
PTP08A-E
1
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
52A
52B
53
54
55
56
57
58
59
60
61
62
STOPPER
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
1
1
4
4
2
2
STARTER RELAY ............................................ 1 ............ AT141011
MACHINE SCREW
RELAY
BASE
CLIP
MACHINE SCREW
2
1
2
4
2
PYCA1
0027104020
0601823240
LY2D US12VDC
0027104020
0602122272
0602123261
M2246700904
M3357201102
0601802149
0601823240
RECTIFIER ..................................................... 1 ............ DE4503
RELAY
MACHINE SCREW
1
2
UNIT, OIL PRESSURE .................................... 1 ............ 108497
UNIT, WATER TEMPERATURE ....................... 1 ............ 02025-00
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
1
1
FUSE............................................................... 2 ............ F-106510A
RECTIFIER ..................................................... 1 ............ DE4503
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 61
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE & RADIATOR ASSY.
EN
PAGE 62 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
1
1-1
1-2
1-3
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
M2923200014
0602041292
0602042595
0602011494
0602060004
0602061000
0012110095
0042510000
M2303200303
0010312030
0040012000
0605000009
0030012000
0040012000
C0923200124
0602011062
M9200100904
0150000016
0016910025
M2313300003
0016910030
M3310500813
M3310500903
0605515148
0605515199
0605515147
B6925200014
0016910030
0602046582
0602046365
0602040650
0602040554
0016908030
M2373100203
0605515146
0605515197
ENGINE, JOHN DEERE ................................. 1 ............ 4045TF275
CARTRIDGE, OIL FILTER, JOHN DEERE...... 1 ............ RE504836
CARTRIDGE, FUEL FILTER, JOHN DEERE .. 1 ............ RE509031
FAN BELT, JOHN DEERE ............................... 1 ............ 240P
BLOWER FAN, JOHN DEERE ........................ 1 ............ RE47518
FAN SPACER, JOHN DEERE ......................... 1 ............ R81911
HEX, HEAD BOLT
SPRINGWASHER
ENGINE FOOT
HEX, HEAD BOLT
SPRINGWASHER
RUBBER SUSPENSION
HEX, NUT
SPRINGWASHER
RADIATOR ....................................................... 1 ............ 232000-3240
CAP ................................................................. 1 ............ 102600-0380
PLUG
O RING
HEX, HEAD BOLT
FAN BRACKET
HEX, HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND ................................................... 3 ............ S/N 840001~8400030
HOSE BAND ................................................... 3 ............ S/N 8400031~
HOSE BAND
FAN MOTOR .................................................... 1 ............ VP-456SKX
HEX, HEAD BOLT
AIR CLEANER ................................................ 1 ............ FPG082527
ELEMENT, AIR CLEANER .............................. 1 ............ PB28889
INDICATOR, AIR CLEANER ............................ 1 ............ RBX00-2252
BAND, AIR CLEANER
HEX, HEAD BOLT
HOSE, AIR CLEANER
HOSE BAND
4
4
2
6
6
2
2
2
7
8
9
10
11
12
12-1
13
14
15
16
17
18
19
20
20
21
22
23
24
24A
25
26
27
28
29
30
1
1
2
1
4
1
1
1
8
1
2
1
1
1
HOSE BAND
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 63
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE & RADIATOR ASSY.
E
PAGE 64 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
60
61
62
63
PART NO.
PART NAME
QTY.
REMARKS
0602022563
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200660
M9300000203
0602010900
M3316100303
0016908020
0199102200
0193600700
0193601000
0605515106
M2326000104
0605515149
M3260600104
0602202592
0027106016
0030006000
M2351800004
0021005070
0040005000
0041205000
0017112025
0040512000
M2325200004
0017110030
0602123282
0602122281
ADAPTER........................................................ 1 ............ 10-M18 X 1.5 F80X-S
90 DEGREE ELBOW
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
COLLAR
MACHINE SCREW
SPRINGWASHER
1
1
1
1
1
1
1
1
1
1
3
1
1
1
3
1
1
1
2
2
4
4
4
4
1
1
1
1
1
PLAIN WASHER
HEX, HEAD BOLT
TOOTHEDWASHER
HOSE CLAMPER
HEX HEAD BOLT
SENDER, WATER SWITCH (ENGINE SIDE)
SENDER, OIL SWITCH (ENGINE SIDE)
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 65
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — OUTPUTTERMINAL ASSY.
OUTPU
PAGE 66 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — 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
M3236100503
M3236100404
0605010040
0027103010
0041203000
0030003000
0016906020
0016906016
M3236400004
M3236300004
0016906020
0601808803
0601808804
M1260700304
0222100150
0016906020
0601812598
0601812538
0027104016
0207004000
M2236100603
0010112045
0041212000
M9310200004
0030012000
0603306775
0027104016
0601815194
0027104016
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX, NUT
10
15
20
5
1
1
2
8
4
8
2
4
1
1
SPRING WASHER
PLAIN WASHER
HEX, HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
PLAIN WASHER
HEX, NUT
HEX, HEAD BOLT
HEX, HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX, HEAD BOLT
CIRCUIT BREAKER ........................................ 2 ............ QOU120B1P 20A
CIRCUIT BREAKER ........................................ 3 ............ QOU250B2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX, HEAD BOLT
RECEPTACLE ................................................. 2 ............ GF530EM 125V 20A X 2
RECEPTACLE ................................................. 3 ............ CS6369 250V 50A
MACHINE SCREW
HEX, NUT
9
10
11
11A
12
13
14
15
16
17
18
19
20
20-1
21
22
23
24
24A
25
26
27
28
29
30
31
32
33
6
1
1
2
10
10
1
2
2
2
2
2
4
TERMINAL COVER
HEX, HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX, NUT
BLIND PLUG
MACHINE SCREW
TERMINAL ...................................................... 1 ............ 601-GP-02
MACHINE SCREW
2
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 67
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — BATTERY ASSY.
BATTERY ASSY.
PAGE 68 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
0602220187
M9310500014
M9103000304
0602220920
M2346900204
M2346900304
BATTERY ........................................................ 1 ............ 627MFD
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
BATTERY CABLE
BATTERY CABLE
1
1
2
1
1
7
8
9
10
CABLE ............................................................ 1 ............ MAKE LOCALLY
0017112025
0040520000
0040512000
HEX, HEAD BOLT
TOOTHEDWASHER
TOOTHEDWASHER
1
1
1
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 69
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 70 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
M2330100703
0017112030
M2333000703
M2333200204
0017110040
M3333200204
0017110035
M2333000603
0017110050
0602325066
MUFFLER
1
4
1
1
4
1
4
1
4
1
HEX, HEAD BOLT
EXHAUST PIPE
GASKET
HEX, HEAD BOLT
GASKET
HEX, HEAD BOLT
EXHAUST PIPE
HEX, HEAD BOLT
CLAMP
9
10
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 71
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 72 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
1-1
1-2
1-3
2
3
4
5
5A
6
7
8
9
10
11
12
13
PART NO.
PART NAME
QTY.
1
1
1
1
6
6
6
3
3
1
2
1
1
3
1
REMARKS
M2363000902
0605505070
0605501073
0605516090
M2363200404
M9310500104
0016908020
0016908040
0207308000
0191302040
0605515109
0191301000
0191301200
0605515109
0605515189
0602042601
0222101000
FUEL TANK
FUEL TANK CAP
FUEL SENDER UNIT
GASKET
TANK BAND
SUPPORTER SHEET
HEX, HEAD BOLT
HEX, HEAD BOLT
HEX, NUT
VENT HOSE
HOSE BAND
SUCTION HOSE
RETURN HOSE
HOSE BAND
HOSE BAND
RETURN PIPE ................................................ 1 ............ RE67050
TANK SHEET
5
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 73
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #1 ASSY.
ENCLO
PAGE 74 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO.
1
2
3
4
5
5
5A
5A
6
PART NO.
PART NAME
QTY.
1
1
REMARKS
M2413001502
M2363300203
0016910030
0603306797
M2423000702
M2423000912
M2493102813
M2493104103
M2423000802
M2423001002
M2493102813
M2493104103
0601851739
0601850100
0016908020
0016910025
M3131400203
M3131400103
M3131400004
0016908020
0016906020
M3423500104
0016906016
M3423200704
0016906020
M3423200804
0016906016
M2310300204
M2310300304
0016906020
M2423300004
M2493600004
0016908020
BASE
ENVIRONMENTAL TANK
HEX, HEAD BOLT
PLUG............................................................... 1 ............ 1-1/2 IN.
12
FRONT FRAME............................................... 1 ............ S/N 8400001TO 8400030
FRONT FRAME............................................... 1 ............ S/N 8400031~
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001TO 8400030
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~
FRONT FRAME............................................... 1 ............ S/N 8400001TO 8400030
FRONT FRAME............................................... 1 ............ S/N 8400031~
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001TO 8400030
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~
GROMMET...................................................... 1 ............ S/N 8400001TO 8400030
6
6A
6A
7
8
9
GROMMET
HEX, HEAD BOLT
HEX, HEAD BOLT
1
26
6
10
11
11A
11B
12
12
13
14
15
16
17
18
19
20
21
22
22A
23
HOSE COVER ................................................. 1 ............ S/N 8400001TO 8400030
HOSE COVER ................................................. 1 ............ S/N 8400031~
HOSE COVER ................................................. 1 ............ S/N 8400031~
HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ......................................... 13 ............ S/N 8400031~
BRACKET
HEX, HEAD BOLT
DUCT COVER
HEX, HEAD BOLT ......................................... 14 ............ S/N 8400001TO 8400030
DUCT COVER
HEX, HEAD BOLT
FAN SHROUD
FAN SHROUD
1
6
2
1
6
1
1
14
1
HEX, HEAD BOLT
DISCHARGE GUIDE
ACOUSTIC SHEET
HEX, HEAD BOLT
1
6
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.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 75
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #1 ASSY.
ENCLO
PART
PANEL TO
YELLOW
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 76 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO.
24
24
24A
25
25
PART NO.
PART NAME
QTY.
REMARKS
M2423201203
M2423201203
M2493103404
0016908020
0016908020
M3433000803
M3433000813
M3493200614
M3493201204
0010114040
0030014000
0040014000
0041214000
0010120050
0030020000
0040020000
0041220000
M2463100102
M2493501304
M2463200102
M2493502203
M3463200704
0016906016
M2463200203
M2493502104
0016908020
M2463400003
0016908020
M2423200804
M2423200814
M2493102604
0016908020
0019208020
0016910025
0019210025
M3310600004
0016908020
0019208020
0016908020
M2483100004
0016908020
0016908020
0040508000
0605503062
M1414800104
0017108020
COVER, FRONT FRAME ................................ 1 ............ S/N 8400001TO 8400030
COVER, FRONT FRAME ................................ 1 ............ S/N 8400031~
ACOUSTIC SHEET
1
HEX, HEAD BOLT ......................................... 27 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ......................................... 27 ............ S/N 8400031~
CENTER FRAME ............................................ 1 ............ S/N 8400001TO 8400030
CENTER FRAME ............................................ 1 ............ S/N 8400031~
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001TO 8400030
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~
HEX, HEAD BOLT
HEX, NUT
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
HEX, NUT
SPRINGWASHER
PLAIN WASHER
ROOF PANEL
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
BACK PLATE
HEX, HEAD BOLT
DUCT
26
26
26A
26A
27
27A
27B
27C
28
28A
28B
28C
29
29A
30
30A
31
32
33
33A
34
35
36
37
37
37A
38
38
39
39
4
4
4
8
4
4
4
8
1
1
1
1
2
12
1
1
10
1
6
ACOUSTIC SHEET
HEX, HEAD BOLT
DUCT COVER
HEX, HEAD BOLT
OVER COVER, FRONT FRAME ..................... 1 ............ S/N 8400001TO 8400030
OVER COVER, FRONT FRAME ..................... 1 ............ S/N 8400031~
ACOUSTIC SHEET
HEX, HEAD BOLT ......................................... 49 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ......................................... 49 ............ S/N 840003~
HEX, HEAD BOLT ........................................... 8 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ........................................... 8 ............ S/N 840003~
COVER, RADIATOR CAP
HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ........................................... 4 ............ S/N 840003~
HEX, HEAD BOLT
COVER, EXHAUST PIPE
HEX, HEAD BOLT
1
40
41
41
42
43
44
45
45A
46
1
6
1
2
1
1
HEX, HEAD BOLT
TOOTHEDWASHER
FUEL LEAK DETECTION SWITCH ................ 1 ............ S/N 840003~
BRACKET ....................................................... 1 ............ S/N 840003~
HEX HEAD BOLT ............................................ 2 ............ S/N 840003~
47
48
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 77
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #2 ASSY.
ENCLOSUR
PAGE 78 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO.
1
1
1A
2
2
2A
3
4
5
5A
6
PART NO.
PART NAME
QTY.
REMARKS
M3443000802
M3443000812
M3493303203
M3443000904
M3443000914
M3493303304
0016908020
0016910025
M2443300903
M2493302204
0016908020
0019208020
M3443200503
M3443600304
0207306000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
0019208020
M2453200602
M2453200612
M2493404604
M2493404614
0016908065
0019208065
REAR FRAME ................................................. 1 ............ S/N 8400001TO 8400020
REAR FRAME ................................................. 1 ............ S/N 8400021~
ACOUSTIC SHEET
DUCT ............................................................... 2 ............ S/N 8400001TO 8400020
DUCT ............................................................... 2 ............ S/N 8400021~
ACOUSTIC SHEET
HEX, HEAD BOLT
HEX, HEAD BOLT
COVER, REAR FRAME
ACOUSTIC SHEET
HEX, HEAD BOLT ......................................... 13 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ......................................... 13 ............ S/N 8400031~
DOOR, REAR FRAME
WINDOW PLATE
HEX, NUT
PLAIN WASHER
DOOR HANDLE ASSY.
MACHINE SCREW
HEX, NUT
1
2
26
4
1
1
6
7
8
9
1
1
8
8
1
4
4
2
2
9A
10
11
11A
12
13
14
14
15
15
15A
15A
16
16
HINGE
WASHER
HEX, HEAD BOLT ........................................... 3 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ........................................... 3 ............ S/N 8400031~
SPLASHER PANEL ......................................... 1 ............ S/N 8400001TO 8400030
SPLASHER PANEL ......................................... 1 ............ S/N 8400031~
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001TO 8400030
ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~
HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ........................................... 4 ............ S/N 8400031~
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.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 79
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #2 ASSY.
ENCLOSU
PAGE 80 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO.
17
18
18A
19
19A
20
20A
21
21A
22
22A
23
23A
24
25
26
27
27
28
29
30
PART NO.
PART NAME
HEX, HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DOOR HANDLE ASSY.
SEAL RUBBER
MACHINE SCREW
HEX, NUT
QTY.
2
1
1
1
1
1
1
1
1
4
4
16
16
6
5
11
REMARKS
0016910025
M2453001703
M2493404704
M2453001803
M2493405104
M2453001503
M2493404504
M2453001603
M2493404404
M9113000002
C9312500004
0021806016
0030006000
M9110100804
M9110100904
M9116100004
0016908020
0019208020
0601850097
0027208025
M9310000004
HINGE
HINGE
WASHER
HEX, HEAD BOLT ......................................... 26 ............ S/N 8400001TO 8400030
HEX, HEAD BOLT ......................................... 26 ............ S/N 8400031~
STOPPER
MACHINE SCREW
CAP
8
8
13
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.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 81
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 82 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
1
3
2
1
4
3
4
3
1
4
1
1
1
2
1
REMARKS
0229200870
0229201130
0229201240
0228900660
0229201070
0229200125
0228901165
0228900770
0228901105
0228900565
0228900820
0228800505
0229201200
0228800635
0228800970
0228800595
0228100640
0228100370
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
9
10
11
12
13
14
15
16
17
18
2
2
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.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 83
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — NAME PLATE ASSY.
NAME PLAT
PAGE 84 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — NAME PLATE ASSY.
NAME PLATE ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550000703
M2550000503
M2552000104
M3550001703
DECAL, NOTE ................................................................ 1 ............. M15000020
DECAL, AUXILIARY ........................................................ 1 ............. M15000070
DECAL, GENERATOR CONTROL .................................. 1 ............. M25000050
DECAL, NOTE ................................................................ 1 ............. M25200010
DECAL, ENGINE OPERATING ....................................... 1 ............. M35000170
......................................................................................................... S/N 8400001~8400030
DECAL, ENGINE OPERATING ....................................... 1 ............. S/N 840031~
DECAL, OPERATING PROCEDURES............................ 1 ............. M35000180A
DECAL, OIL DRAIN PLUG.............................................. 1 ............. M90000000
DECAL, WATER .............................................................. 1 ............. M90010000
......................................................................................................... S/N 8400001~8400030
DECAL, WATER .............................................................. 1 ............. M90010000
......................................................................................................... S/N 840031~
DECAL, NEGATIVE ........................................................ 1 ............. M90030000
DECAL, POSITIVE ......................................................... 1 ............. M90030010
DECAL, DIESEL FUEL ................................................... 1 ............. M90050000
DECAL, WARNING MOVING PARTS .............................. 2 ............. M90300000
DECAL, WATER - OIL CHECK ........................................ 1 ............. M90300010
DECAL, WARNING HOT COOLANT ............................... 1 ............. M90310000
......................................................................................................... S/N 8400001~8400030
DECAL, WARNING HOT COOLANT ............................... 1 ............. M90310000
......................................................................................................... S/N 840031~
DECAL, WARNING ENGINE EXHAUST ......................... 1 ............. M90320000
DECAL, FLUID DRAIN .................................................... 1 ............. M91000000
DECAL, CAUTION HOT PARTS ...................................... 1 ............. M91010000
DECAL, CAUTION .......................................................... 1 ............. M91010040
DECAL, GROUND ........................................................... 1 ............. M92000000
DECAL, AMMETER CHANGE-OVER SW. ..................... 1 ............. M92000010
DECAL, VOLTMETER CHANGE-OVER SW.................... 1 ............. M92000020
DECAL, START CONTACT ............................................. 1 ............. M92000050
DECAL, WARNING ELECTRIC SHOCK HAZARD .......... 2 ............. M92010000
5
5
6
7
8
M3550002003
M3550001803
M9500000004
M9500100004
8
M9500100004
9
M9500300004
M9500300104
M9500500004
M9503000004
M9503000103
M9503100004
10
11
12
13
14
14
M9503100004
15
16
17
18
19
20
21
22
23
M9503200004
M9510000004
M9510100004
M9510100403
M9520000004
M9520000104
M9520000204
M9520000504
M9520100004
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.
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 85
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — NAME PLATE ASSY.
NAME PLA
PAGE 86 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
DCA-85USJ — NAME PLATE ASSY.
NAME PLATE ASSY.
NO.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
PART NO.
PART NAME
QTY.
REMARKS
M9520100204
M9520100304
M9520100404
M9520100503
M9520100603
M9520200003
0021106016
DECAL, CAUTION .................................................... 1 ..............M92010020A
DECAL, SAFETY INSTRUCTIONS .......................... 1 ..............M92010030
DECAL, DANGER HIGHVOLTAGE .......................... 1 ..............M92010040
DECAL,WARNING ................................................... 1 ..............M92010050
DECAL, CAUTION .................................................... 2 ..............M92010060
DECAL, CONNECTION OF OUTPUT CABLE ......... 1 ..............M92020000
MACHINE SCREW................................................... 4 ..............S/N 8400031~
DECAL, MQ.............................................................. 1 .............. M91220000
M9512200004
M9510200304
M3560102004
M2560100603
M3560102204
M2560100703
M2560100803
M3560102504
M9510100304
DECAL, MQ POWER
STRIPE
STRIPE, WHISPERWATT
STRIPE
STRIPE, 85
STRIPE, 85
3
2
2
2
1
1
2
STRIPE
DECAL, ENVIRONMENTALWARNING .................... 1 ..............M91010030
...................................................................................................S/N 8400031~
PLATE, MQ POWER ................................................ 1 ..............S/N 8400031~
40
0600500092
1
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 87
Download from Www.Somanuals.com. All Manuals Search And Download.
Effective:October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Partsmustbeinnewandresalablecon- forpricedeclinesandaddedchargesforprice
dition,intheoriginalMultiquippackage(if increaseswillnotbemadeforstockonhandat
any), and with Multiquip part numbers thetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
clearlymarked.
Multiquip reserves the right to quote and sell
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifest has been obtained from the carrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
b. Any parts with a limited shelf life A$35.00surchargewillbeaddedtotheinvoice
(such as gaskets, seals, “O” rings, forspecialhandlingincludingbusshipments,
andotherrubberparts)thatwerepur- insuredparcelpostorincaseswhereMultiquip
chasedmorethansixmonthspriorto mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
thereturndate.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
netpriceoflessthan$5.00.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremadein
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
neitherassumesnotauthorizesanypersonto
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.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification, pending
instructions. If a reply is not received
within five days, the material will be re-
turnedtothesenderathisexpense.
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
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All datewillbebilledattherevisedprice.Rebates
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 88 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 89
Download from Www.Somanuals.com. All Manuals Search And Download.
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
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
Download from Www.Somanuals.com. All Manuals Search And Download.
|