OPERATION AND PARTS MANUAL
®
MODEL DCA85USJ2
60HZ GENERATOR
(JOHN DEERE 4045HF285 DIESEL ENGINE)
PARTS LIST NO. M2870400404C
Revision #1 (03/22/11)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
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PROPOSITION 65 WARNING
Diesel engine exhaust and some of
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REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 3
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TABLE OF CONTENTS
COMPONENT DRAWINGS
DCA-85USJ2 Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Table Of Contents.................................................... 4
Parts Ordering Procedures...................................... 5
Safety Information .............................................. 6-11
Specifications ........................................................ 12
Dimensions............................................................ 13
Installation ........................................................ 14-15
General Information............................................... 16
Major Components ................................................ 17
Diagnostic Display............................................ 18-34
Generator Control Panel........................................ 35
Engine Operating Panel.................................... 36-37
Output Terminal Panel Familiarization .............. 38-40
Load Application.................................................... 41
Generator Outputs................................................. 42
Generator Outputs/Gauge Reading....................... 43
Output TerminaL Panel Connections................ 44-45
Inspection/Setup............................................... 46-49
Generator Start-Up Procedure ........................ 50-51
Generator Shut-Down Procedures ........................ 52
Maintenance..................................................... 53-55
Trailer Maintenance .......................................... 56-59
Trailer Wiring Diagram ........................................... 60
Generator Wiring Diagram..................................... 61
Engine Wiring Diagram.......................................... 62
Troubleshooting (Generator).................................. 63
Troubleshooting (Engine Controller)...................... 64
Troubleshooting (Diagnostic Lamp)....................... 65
Explanation Of Code In Remarks Column............. 66
Suggested Spare Parts ......................................... 67
Generator Assembly......................................... 68-69
Control Box Assembly ...................................... 70-73
Engine And Radiator Assembly........................ 74-77
Output Terminal Assembly................................ 78-79
Battery Assembly.............................................. 80-81
Muffler Assembly.............................................. 82-83
Fuel Tank Assy. ................................................ 84-85
Enclosure (1) Assembly.................................... 86-89
Enclosure (2) Assembly.................................... 90-93
Rubber Seals Assembly ................................... 94-95
Nameplate and Decals Assembly .................... 96-99
Terms And Conditions Of Sale — Parts .............. 100
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Goto www.multiquip.com and click on
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
Order via Phone:
1-800-427-1244
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
❒
❒
❒
❒
❒
Dealer Name and Address
✓ UPS/Fed Ex
✓ DHL
✓ Truck
■
■
Priority One
Ground
Shipping Address (if different than billing address)
Return Fax Number
■ Next Day
Second/Third Day
Applicable Model Number
■
Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 5
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SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. 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.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SAFETY MESSAGES
The four 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 four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
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SAFETY INFORMATION
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment.Damage
to the equipment and/or injury to user may result.
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
WARNING
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death.Disconnection of any of these
devices will void all warranties.
NOTICE
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
CAUTION
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 7
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SAFETY INFORMATION
ENGINE SAFETY
DANGER
NOTICE
NEVER run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied.When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition.It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
PAGE 8 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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SAFETY INFORMATION
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
ALWAYS make sure the trailer is equipped with a safety
chain.
DO NOT fill the fuel tank while the engine is running
or hot.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
DOT Requirements include the following:
• Connect and test electric brake operation.
NEVER use fuel as a cleaning agent.
• Secure portable power cables in cable tray with tie
wraps.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
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.
TOWING SAFETY
CAUTION
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
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 to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Refer to MQ Power trailer manual for additional safety
information.
Place chock blocks underneath wheel to prevent rolling
while parked.
In order 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 mechanically sound and in good
operating condition.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
ALWAYS shutdown engine before transporting
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 9
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SAFETY INFORMATION
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
duringoperationcancauseelectrocution,
electrical shock or burn.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
The electrical voltage required to
operate the generator can cause severe
Grounding Safety
DANGER
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) 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.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous.The possibility exists
of electrical shock, electrocution or
death.
NEVER use gas piping as an electrical ground.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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SAFETY INFORMATION
BATTERY SAFETY
DANGER
ENVIRONMENTAL SAFETY
NOTICE
DO NOT drop the battery. There is a possibility that the
battery will explode.
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
WARNING
ALWAYSwearsafetyglasseswhenhandling
the battery to avoid eye irritation.The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS recharge the battery in a well-ventilated
environmenttoavoidtheriskofadangerousconcentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 11
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SPECIFICATIONS
Table 1. Generator Specifications
DCA-85USJ2
Model
Type
Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Zigzag
Single
66 KW
60 KW
Standby Output
Prime Output
75 KW (94 kVA)
68 KW (85 kVA)
3Ø Voltage (L-L/L-N)
Voltage Selector Switch at 3Ø 240/139
208Y/120, 220Y/127,
240Y/139
N/A
N/A
3Ø Voltage (L-L/L-N)
Voltage Selector Switch at 3Ø 480/277
416Y/240, 440Y/254,
480Y/277
1Ø Voltage (L-L/L-N)
Voltage Selector Switch at 1Ø 240/120
N/A
0.8
240/120
1.0
Power Factor
Frequency
60 Hz
Speed
1800 rpm
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
5,094 lbs. (2,310 kg.)
6,048 lbs. (2,743 kg.)
Wet Weight
Table 2. Engine Specifications
Model
Type
John Deere 4045HF285 Tier 3
4 cycle, water-cooled, direct injection, turbo-charged
air to air intercooled
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
4 cylinders
4.19 in. x 5.00 in. (106 mm x 127 mm)
275 cu. in. (22,928 cc)
115 HP at 1800 rpm
Electric
Coolant Capacity
Lube Oil Capacity
Fuel Type
3.70 gal. (14.0 liters
3.88 gal. (14.7 liters)
#2 Diesel Fuel
Fuel Tank Capacity
126 gal. (475 liters)
5.3 gal. (20.1 L)/hr at full load 4.3 gal. (16.2 L)/hr at 3/4 load
Fuel Consumption
Battery
3.1 gal. (11.9 L)/hr at 1/2 load
2.0 gal. (7.6 L)/hr at 1/4 load
27 (CCA 0° 800A) x 1
PAGE 12 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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DIMENSIONS
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
B
C
D
42.51 in. (1080 mm.)
32.13 in. (816 mm.)
33.30 in. (846 mm.)
32.13 in. (816 mm.)
F
G
H
112.20 in. (2,850 mm.)
71.26 in. (1,810 mm.)
48.82 in. (1240 mm.)
E
33.30 in. (846 mm.)
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 13
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INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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INSTALLATION
OUTDOOR INSTALLATION
GENERATOR GROUNDING
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
The installation site must be relatively free from moisture
and dust.All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves.The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
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.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
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.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 15
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GENERAL INFORMATION
GENERATOR
OPEN DELTA EXCITATION SYSTEM
This generator (Figure 3) is 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.
This generator is equipped with the state of the art “Open-
Delta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
ENGINE OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Panel Light/Panel Light Switch
ECU Controller
Engine Speed Switch
Emergency Stop Lamp
Warning Lamp
Pre-Heat Lamp
Fuel Leak Detected Alarm Lamp
Diagnostic Gauge
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities.The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
ENGINE
AC Ammeter (Amps)
This generator unit incorporates an John Deere 6068HF285
diesel engine. This engine is designed to meet every
performance requirement for the generator. Reference
Table 2 for engine specifications.
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)
• Automatic Voltage Regulator
• Current Transformer
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
• Over-Current Relay
• Starter Relay
• Voltage Selector Switch
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
EXTENSION CABLES
OUTPUT TERMINAL PANEL
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
PAGE 16 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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MAJOR COMPONENTS
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Muffler Assembly
1
2
3
4
5
6
7
8
9
Engine Assembly
Air Filter Assembly
Generator Assembly
Battery Assembly
Output Terminal Assembly
Fuel Tank Assembly
Generator Control Panel Assembly
Engine Operating Panel Assembly
Figure 3. Major Components
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DIAGNOSTIC DISPLAY
2. Left Arrow Button – Press this button to scroll through
the screen either moving the parameter selection
toward the left or upward.
3. Right Arrow Button – Press this button to scroll
through the screen either moving the parameter
selection toward the right or downward.
4. Enter Key Button – Press this button to select the
parameter that is highlighted on the screen.
5. Emergency Stop LED – When lit (RED) indicates a
major fault has occured. This condition will shudown
the generator.
6. Warning LED – When lit (AMBER), indicates a engine
parameter has exceeded its limits (minor fault). The
generator will still run in this condition.
Figure 4. Diagnostic Display
The diagnostic display panel located inside the control box
on the generator (Figure 4) is designed to meet the needs
for instrumentation and control of electronically controlled
engine communication using the SAEJ1939 Controller Area
Network (CAN). This diagnostic display is a multifunction
tool that enables equipment operators to view many
different engine parameters and service codes.
7. Display Screen – Graphical backlight LCD screen.
Back lighting is controlled via menu or external
dimmer potentiometer. The display can show either a
single parameter or a quadrant display showing four
parameters simultaneously.
8. Diagnostic Switch – When placed in the ON position,
will activate the diagnostic display panel.
The keypad on the diagnostic display panel is a capacitive
touch sensing system. There are no mechanical switches
to wear or stick. This keypad (display unit) will operate in
extreme hot or cold weather conditions.
9. CAN Diagnostic Connector – Controller Area
Network connector.This connector outputs diagnostic
error codes. Connect a scanner or similar device into
this connector to read error codes.
Other components in the system are microprocessor-based
components for displaying critical engine data broadcast
by an electronic engine or transmission’s Engine Control
Unit (ECU):engine RPM, oil pressure, coolant temperature,
system voltage, etc., and a combination audible alarm and
relay unit for warning and shutdown annunciation.
Display Parameters
The following are some of the engine and transmission
parameters displayed on the diagnostic disply panel.
Engine RPM’s
Engine Hours
System Voltage
% Engine Load at current RPM
Coolant Temperature
Oil Pressure
Fuel Economy
Current Fuel Consumption
Throttle Position
Engine Manifold Air Temperature
Active Service Codes
The Engine Control Unit (ECU) used with this generator
diagnosis engine faults that arise with the the engine
control system and the engine itself. Engine faults can
be determined by viewing the Diagnostic Trouble Codes
(Active Fault Codes) which are displayed on the Diagnostic
Display Panel. See the John Deere Engine Operator’s
Manual for a complete listing of active fault codes and
countermeasures.
The following definitions describe the controls and functions
of the Diagnostic Display Panel (Figure 4).
1. Menu Button – Press this button to enter or exit menu
screens.
Set Units for Display (English or Metric)
English Configuration Parameters.
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DIAGNOSTIC DISPLAY
2. The first seven items of the “Main Menu” will be
displayed. Touching the “Arrow Buttons” will scroll
through the menu selection.
First Time Start Up
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence. Once the “Wait
to Start” message is no longer displayed the operator
may start the engine. Note: Displays only when SAE
J1939 message is supported by engine manufacture.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
WAIT TO
START
PREHEAT
4. Touch the Arrows” to scroll to the desired menu item
or touch “Menu” to exit the Main menu and return to
the engine parameter display.
3. Once the engine has started the single engine
parameter is displayed.
1000 RPM
98%
ENG RPM
0
1500
3000
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
Selecting a Language
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted
touch the “Enter” button.
Main Menu Navigation
1. Starting at the single or four engine parameter display,
touch “Menu”.
GO TO 1-UP DISPLAY
LANGUAGES
1000 RPM
98%
ENG RPM
0
3000
LOAD RPM
1500
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
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DIAGNOSTIC DISPLAY
4. If the word “MORE”appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.
2. The language choices will be displayed. Use the
“Arrow” buttons to scroll through the selections and
touch “Enter” to make a selection.
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
3. Now that you have selected the language, touch the
“Menu” button to return to the main menu display.
5. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Stored Fault Codes
1. Starting at the single or the four engine parameter
display touch the “Menu button.”.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
1000 RPM
98%
ENG RPM
LOAD RPM
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1000 RPM
98%
14.2
57 PSI
ENG RPM
0
1500
3000
LOAD RPM
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
Engine Configuration Data
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
Stored Fault Codes is highlighted.
1. Starting at the single or four engine parameter display
touch the “Menu Button”. First Time Start Up
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1000 RPM
98%
ENG RPM
0
1500
3000
LOAD RPM
ADJUST BACKLIGHT
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button”to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters).
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
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DIAGNOSTIC DISPLAY
2. The The first seven items of the “Main Menu” will be
displayed. Touching the “Arrow Buttons” will scroll
through thr menu selection.
First Time Start-Up
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence. Once the “Wait
to Start” message is no longer displayed the operator
may start the engine. Note: Displays only when SAE
J1939 message is supported by engine manufacturrg.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
WAIT TO
START
PREHEAT
4. Touch the Arrows” to scroll to the desired menu item
or touch “Menu” to exit the Main menu and return to
the engine parameter display.
3. Once the engine has started the single engine
parameter is displayed.
1000 RPM
98%
0
3000
ENG RPM
1500
LOAD RPM
1800 RPM
TEMP
ENG RPM COOL
14.2
57 PSI
BATT VOLT
OIL PRES
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
Selecting a Language
Main Menu Navigation
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted
touch the “Enter” button.
1. Starting at the single or four engine parameter display,
touch “Menu”.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONFG
1000 RPM
98%
ENG RPM
0
3000
LOAD RPM
1500
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
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DIAGNOSTIC DISPLAY
2. The language choices will be displayed. Use the
“Arrow” buttons to scroll through the selections and
touch “Enter” to make a selection.
4. f the word“MORE”appears above the“Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.).
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
3. Now that you have selected the language, touch the
“Menu” button to return to the main menu display.
5. Touch the “Menu Button to return to the main menu.
Stored Fault Codes
1. Starting at the single or the four engine parameter
display touch the “Menu button”.
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
1000 RPM
98%
MORE
HIDE
ENG RPM
0
1500
3000
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
Stored Fault Codes is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
1000 RPM
98%
ENG RPM
LOAD RPM
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
GO TO 1-UP DISPLAY
STORED CODES
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Engine Configuration Data
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button”to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
1000 RPM
98%
ENG RPM
0
1500
3000
LOAD RPM
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
GO TO 1-UP DISPLAY
STORED CODES
BATT VOLT
OIL PRES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
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DIAGNOSTIC DISPLAY
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Engine Configuration”menu item has been highlighted
.
FAULTS AND WARNING
Auxiliary Gage Fault
1. During normal operation the single or four parameter
screen will be displayed.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1000 RPM
98%
ADJUST BACKLIGHT
ENG RPM
0
3000
LOAD RPM
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
3. Once the “Engine Configuration” menu item has been
highlighted touch the “Enter Button” to view the engine
configuration data.
2. The PVA Series of auxiliary gages can be attached to
the PowerView. These auxiliary gages communicate
with the Modbus master PowerView via a daisy-chained
RS-485 port. If at any time during system initialization
or normal operation an auxiliary gage should fail, the
single or four parameter screen will be replaced with
the “MLink Gage Fault” message.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1
of
x
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
4. Use the “Arrow Buttons” to scroll through the engine
configuration data.
HIDE
ENGINE SPEED PT 1
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display, touch the “Enter
Button.
1800 RPM
MORE
1
of
x
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
5. Touch the “Menu Button” to return to the main menu.
HIDE
ENGINE SPEED PT 1
1800 RPM
4. The display will return to the single or four parameter
screen.
MORE
!
1000 RPM
98%
0
1500
3000
ENG RPM
LOAD RPM
1800 RPM
ENG RPM COOL TEMP!
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
!
14.2
57 PSI
BATT VOLT
OIL PRES
!
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DIAGNOSTIC DISPLAY
4. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter
Button”.
!
!
!
Indicates Auxiliary Gage Fault
Indicates Fault Warning
Indicates Derate or Shutdown Condition Fault
5. Touching the “Enter Button” will redisplay the hidden
fault. Touching the “Enter Button” once again will hide
the fault and return the screen to the single or four
parameter display.NOTE:The fault can only be cleared
by correcting the cause of the fault condition.
1
of
x
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1
of
x
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
5. The display will return to the single or four parameter
display but the display will contain the “Active Fault”
warning icon.Touching the “Enter Button”will redisplay
the hidden fault.
HIDE
Active Fault Codes
1000 RPM
98%
!
3000
ENG RPM
LOAD RPM
0
1500
!
1800 RPM
ENG RPM COOL TEMP!
1. During normal operation the single or four parameter
screen will be displayed
14.2
57 PSI
BATT VOLT
OIL PRES
!
125°F
COOL TEMP
1000 RPM
98%
1000 RPM
ENG RPM
LOAD RPM
ENG RPM
143°F
OIL TEMP
6. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four
parameter display.
57 PSI
14.2
57 PSI
OIL PRES
BATT VOLT
OIL PRES
1
of
x
WARNING
2. When the PowerView receives a fault code from an
engine control unit the single or four parameter screen
will be replaced with the “Active Fault Codes”message.
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
1
of
x
WARNING
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
7. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
3. If the word “MORE”appears above the “Arrow Buttons”,
there are more active fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next “Active
Fault Code”.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
1000 RPM
98%
ENG RPM
LOAD RPM
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1
of
x
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
SPN110 FMI10
HIGH COOLANT TEMP
MORE
HIDE
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DIAGNOSTIC DISPLAY
5. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four
parameter display.
Shutdown Codes
1. During normal operation the single or four parameter
screen will be displayed
1
of
x
SHUTDOWN
SPN110 FMI10
HIGH COOLANT TEMP
1000 RPM
98%
ENG RPM
0
3000
LOAD RPM
1500
MORE
HIDE
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
2. When the diagnostic display receives a severe fault
code from an engine control unit the single or four
parameter screen will be replaced with the “Shutdown”
message.
1000 RPM
!
98%
ENG RPM
LOAD RPM
0
1500
3000
1
of
x
SHUTDOWN
!
1800 RPM
ENG RPM COOL TEMP!
14.2
57 PSI
BATT VOLT
OIL PRES
SPN110 FMI10
HIGH COOLANT TEMP
!
MORE
HIDE
Bachlight Adjustment
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter Button
”
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
1
of
x
SHUTDOWN
!
1000 RPM
98%
ENG RPM
0
1500
LOAD RPM
3000
1800 RPM
ENG RPM COOL TEMP!
!
SPN110 FMI10
HIGH COOLANT TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
MORE
HIDE
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Adjust Backlight” is highlighted.
4. .The display will return to the single or four parameter
display, but the display will contain the “Shut Down”
icon. Touching the “Enter Button” will redisplay the
hidden fault.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
!
1000 RPM
98%
0
1500
3000
ENG RPM
LOAD RPM
ADJUST BACKLIGHT
1800 RPM
ENG RPM COOL TEMP!
!
14.2
57 PSI
BATT VOLT
OIL PRES
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DIAGNOSTIC DISPLAY
CONTRAST ADJUSTMENT
3. Once the “Adjust Backlight” menu item has been
highlighted touch the “Enter Button” to activate the
“Adjust Backlight” function
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
1000 RPM
98%
ENG RPM
LOAD RPM
0
3000
1500
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
ADJUST BACKLIGHT
OIL PRES
4. Use the “Arrow Buttons” to select the desired backlight
intensity..
2. The main menu will pop up on the display. Use the
“Arrow Buttons”to scroll through the menu until “Adjust
Contrast” is highlighted.
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
5. Touch the “Menu Button” to return to the main menu.
3. Once the “Adjust Contrast” menu item has been
highlighted touch the “Enter Button” to activate the
“Adjust Contrast” function.
ADJUST BACKLIGHT
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST CONTRAST
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display
4. Use the “Arrow Buttons” to select the desired contrast
intensity
GO TO 1-UP DISPLAY
1000 RPM
98%
ENG RPM
LOAD RPM
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
ADJUST CONTRAST
5. Touching the “Menu Button” will take you back through
the menus.
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DIAGNOSTIC DISPLAY
5. Touch the “Enter Button”to select the highlighted units.
Select Units
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
ENGLISH
METRIC KPA
METRIC BAR
1000 RPM
98%
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Touch the “Menu Button” to return to the “Main Menu”
.
ENGLISH
*
METRIC KPA
METRIC BAR
2. The main menu will pop up on the display. Use the
arrow buttons to scroll through the menu until the
“Select Units” is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
7. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
1000 RPM
98%
ENG RPM
LOAD RPM
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
14.2
57 PSI
BATT VOLT
OIL PRES
ADJUST BACKLIGHT
3. Once the“Select Units”menu item has been highlighted
touch the “Enter Button” to access the “Select Units”
function.
SETUP 1-UP DISPLAY
1. Starting at the single engine parameter display, touch
the “Menu Button”.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
1000 RPM
98%
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
4. Use the arrows to highlight the desired units.“English”
for imperial units i.e. PSI,”F or Metric kPa, Metric Bar
for IS units i.e. kPa, Bar, “C".
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Setup 1-up Display” is highlighted.
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
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DIAGNOSTIC DISPLAY
3. Once the “Setup 1-up Display” menu icon has been
highlighted touch the “Enter Button” to access the
“Setup 1-up display” function.
7. A message indicating the “Single Engine” parameter
display parameters are reset to the factory defaults will
be displayed, then the display will return to the “Custom
Setup” menu.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
RESTORED TO
DEFAULTS
ADJUST BACKLIGHT
4. Three options are available for modification of the
1-Up display.
8. Custom Setup- To perform a custom setup of the 1-Up
Display, use the arrow buttons to scroll to and highlight
“Custom Setup” on the display.
a. Use Defaults — This option contains a set of engine
parameters: Engine Hours, Engine RPM. System
Voltage, Battery Voltage, % Engine Load at Current
RPM, Coolant Temperature, Oil Pressure.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
b. Custom Setup — This option allows for the
modification of what parameter, the number of
parameters, and the order in which the parameters
are being displayed.
c. Automatic Scan — Selecting the scan function
will cause the 1-Up Display to scroll through
the selected set of parameters one at a time,
momentarily pausing at each.
9. Touching the “Enter Button” will display a list of engine
parameters.
5. Use Defaults- To select “Use Defaults” use the arrow
buttons to scroll to and highlight “Use Defaults” in the
menu display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
10. Use the “Arrow Buttons” to scroll to and highlight a
selected parameter (parameter with a # symbol to right
of it).
6. Touch the “Enter Button” to activate the “Use Defaults”
function.
1
3
2
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
This number indicates
the order of display for the
parameters and that the
parameter is selected
for display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
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DIAGNOSTIC DISPLAY
11. Touch the “Enter Button” to deselect the selected
parameter removing it from the list of parameters being
displayed on the 1-up display.
16. Touching the “Enter Button” toggles the “Automatic
Scan” function on.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
1
3
2
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
17. Touching the “Enter Button” again toggles the
“Automatic Scan” function off.
12. Use the “Arrow Button” to scroll and highlight the
desired parameter that has not been selected for
display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
Note that the numbers
now indicate the new order
of display for the parameters.
18. Once the “Use Defaults”, “Custom Setup” and
“Automatic Scan” functions have been set touch the
“Menu Button” to return to the main menu.
13. Touch the “Enter Button” to select the highlighted
parameter for inclusion in the Single Engine Parameter
Display.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
3
19. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
14. Continue to scroll and select additional parameters for
the custom 1-up Display. Touch the “Menu Button” at
any time to return to the “Custom Setup” menu.
GO TO 1-UP DISPLAY
0
3000
1500
STORED CODES
ENGINE CONFG
15. Automatic Scan- Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time. Use the “Arrow Buttons” to
scroll to the “Automatic Scan” function.
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
1800 RPM
ENG RPM COOL TEMP
ADJUST BACKLIGHT
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
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DIAGNOSTIC DISPLAY
Setup 4-Up Display
5. The “Use Defaults” screen will be displayed during the
resetting period then will automatically return to the
“Setup 4- Up Display” menu.
1. From the single or four engine parameter display touch
the “Menu Button
1000 RPM
98%
RESTORED TO
DEFAULTS
ENG RPM
LOAD RPM
0
3000
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Select the “4-Up Custom Setup” from the “4-Up Setup”
menu.
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Setup 4-Up Display” is highlighted.
USE DEFAULTS
CUSTOM SETUP
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
7. The quadrant with the backlit parameter value is the
current selected parameter. Use the “Arrow Buttons”
to highlight the parameter value in the quadrant you
wish to place a new parameter.
3. Once the “Setup 4-Up Display” menu item has been
highlighted touch the “Enter Button” to activate the
“Setup 4- Up Display” menu.
USE DEFAULTS
CUSTOM SETUP
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
8. Touch the “Enter Button” and a list of parameters will
appear.
4. Touch the “Enter Button” to activate the “Use Defaults”
function. This action will reset the unit to the factory
default.
125°F
COOL TEMP
1000 RPM
ENG RPM
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
14.2
BATT VOLT
57 PSI
OIL PRES
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DIAGNOSTIC DISPLAY
9. The parameter that is highlighted is the selected
parameter for the screen. Use the “Arrow Buttons” to
highlight the new parameter to be placed in the
quadrant selected in the previous screen.
14. Touch the “Menu Button” to return to the main menu.
125°F
COOL TEMP
1000 RPM
ENG RPM
143°F
OIL TEMP
57 PSI
OIL PRES
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
3
1
The number to the right
of the parameter indicates
the quadrant in which it
is displayed.
2
1= Upper Left Quadrant
4
2
3
4
=
=
=
Lower Left Quadrant
Upper Right Quadrant
Lower Right Quadrant
15. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
GO TO 1-UP DISPLAY
125°F
1000 RPM
STORED CODES
ENG RPM
ENGINE CONFG
10. Touch the “Enter Button” to change the selected
parameter in the quadrant to the new parameter.
COOL TEMP
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
143°F
OIL TEMP
57 PSI
OIL PRES
SELECT UNITS
ADJUST BACKLIGHT
ENGINE SPEED
ENGINE HOURS
3
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
1
2
4
Utilities (information and troubleshooting)
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
11.
Use the “Menu Button” to return to the “4-Up
Custom Setup” screen.
125°F
COOL TEMP
1000 RPM
0
3000
1500
ENG RPM
1800 RPM
ENG RPM COOL TEMP
143°F
OIL TEMP
57 PSI
OIL PRES
ENGINE SPEED
ENGINE HOURS
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL TEMPERATURE
ENGINE OIL PRESSURE
3
1
2
4
Note the number to
the right of the selected
parameter indicating that the
parameter is now assigned
to that display location
2. The main menu will be displayed. Use the “Arrow
Buttons” to scroll through the menu until the “Utilities”
is highlighted.
12. The parameter in the selected quadrant has changed
to the parameter selected in the previous screen.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
125°F
COOL TEMP
1000 RPM
ENG RPM
143°F
OIL TEMP
57 PSI
OIL PRES
3. Once the “Utilities” menu item has been highlighted,
touch the “Enter Button” to activate the “Utilities”
functions.
13. Repeat the parameter selection process until all spaces
are filled.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
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DIAGNOSTIC DISPLAY
8. When the gage data has cleared, the display
automatically returns to the “Utilities” menu. Scroll to
“SoftwareVersion”.Touch “Select” to view the software
version currently in the diagnostic display.
4. Touch “Select” to enter the “Gage Data” display.When
“GageData”isselectedthePowerViewwillcommunicate
with the analog gages at a fixed rate of 38.4k Band, 8
data bits, no parity check, 1 stop bits, half duplex.
GAGE DATA
SOFTWARE
VERSION
MURPHY: X.XX
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
ADJUST BACKLIGHT
DEMO MODE ON
9. Touch “Menu” to return to “Utilities”. Highlight Fault
Conversion”using the “Arrows”.Touch “Select”to enter
the Fault conversion menu.
5. Use the “Arrow Buttons” to scroll through the items or
touch “Menu” to return to the “Utilities” menu.
GAGE DATA
1
of
x
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT CONVERSION
ENGINE OIL PRESSURE
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
10. Use the “Arrows” to scroll to and highlight the desired
version then touch “Select”.An asterisk denotes which
version is currently selected.
6. Touch “Menu Button” to return to the “Utilities” menu.
NOTICE
1
of
x
ENGINE OIL PRESSURE
There are four (4) different methods for converting fault
codes. The diagnostic display always looks for J1939
Version 4 and can be set to read the code as one of
three (3) other J1939 versions if Version 4 is not being
used. Most engine ECU’s use Version 4, therefore in
most cases adjustment of this menu option will not be
required.
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
7. Use the “Arrows”to highlight Remove All Gages”.Touch
“Select” to clear gage data from memory. It takes a
moment to clear all gages.
Upon receiving an unrecognizable fault, change to a
different J1939Version.If the fault SPN does not change
when the version is changed, the ECU generating the
fault is using Fault Conversion method 4. If the SPN
number does not change but is still unrecognizable, try
changing to another J1939 Version not yet used and
continue to check the SPN number.
CLEARING GAGES
PLEASE WAIT
J1939 VERSION 1
J1939 VERSION 2
J1939 VERSION 3
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DIAGNOSTIC DISPLAY
11. Touch the “Menu” button to return to “Utilities” menu.
Touch the “Menu button again to return to the “Main”
menu.
4. Use the “Arrows” to scroll down to and highlight either
the “Slave Active or Master Active” modes. Touch the
“Enter” button to toggle between master and slave.
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
ADJUST BACKLIGHT
UTILITIES
MODBUS SETUP
5. Use the “Arrows” to scroll to the “Serial Port” menu to
highlight it, then touch “Enter”.
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
1000 RPM
98%
ENG RPM
0
3000
LOAD RPM
1500
1800 RPM
ENG RPM COOL TEMP
14.2
57 PSI
BATT VOLT
OIL PRES
6. Use the “Arrow” button to scroll to each selection to
configure the MODBUS values for your application.
2. The main menu will be displayed. Use the “Arrow
Buttons” to scroll through the menu until the “Utilities”
is highlighted, then touch “Enter”.
BAUD RATE
PARITY
DATA BITS
STOP BITS
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
UTILITIES
7. When finished, touch “Menu” to return to the previous
screen.
3. Once in the “Utilities” menu use the “Arrows” to scroll
through the menu until the “Modbus Setup” menu is
highlighted, then touch “Enter”.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 33
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DIAGNOSTIC DISPLAY
GLOSSARY (Troubleshooting Information)
CANBUS FAILURE
Diagnostic Display has not received any CAN messages for at least 30 seconds.
NO DATA
Diagnostic Display has not received the particular message being displayed for at least 5 seconds.
NOT SUPPORTED
Diagnostic Display has received a message from the ECU stating the displayed message is not supported
DATA ERROR
Diagnostic Display has received an error message from the ECU for the displayed message.
EMPTY
No parameter selected for this 4- UP quadrant.
WAIT TO START PREHEATING
This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING
The ECU did not respond to the PowerView request.
NO GAGE DATA
The Diagnostic Display has no record of connected gages to the RS485 bus.
DISPLAY NOT VISIBLE
Press and hold the “Menu” button for approximately 3 seconds.
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GENERATOR CONTROL PANEL
2
5
INCREASE
DECREASE
1
V
U
W
3
AUTO
MANUAL
6
7
OFF/RESET
OFF
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
V-W
OFF
ENGINE RUNNING
U-V
W-U
4
MOOOOO-20001Q
Figure 5. Generator Control Panel
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 5).
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.
1. Main Circuit Breaker—This three-pole, 250A main
breaker is provided to protect the the U,V, and W
Output Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
2. Voltage Regulator Control — Allows 15% manual
adjustment of the generator’s output voltage.
Over-Current Relay
3. Ammeter Change-Over Switch —This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals,
or to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
4. 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.
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
5. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
In the event of a short circuit or over current condition,
it will automatically trip the 250 amp main breaker.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
To restore power to the OutputTerminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
7. ACVoltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
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ENGINE OPERATING PANEL
6
11
10
1
2
INCREASE
DECREASE
13
12
7
V
U
W
AUTO
MANUAL
14
OFF/RESET
OFF
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
3
4
OVERSPEED
V-W
ENGINE RUNNING
W-U
U-V
MOOOOO-20001Q
OFF
8
9
5
Figure 6. Engine Operating Panel
The definitions below describe the controls and functions
of the Engine Operating Panel (Figure 6).
5. 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.
1. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. (241~448
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the
oilpressure should return to the correct pressure range.
6. 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. Water Temperature Gauge – During normal operation
this gauge be should read between 180° and 221°F. (82°
C and 110° C
7. Panel Light Switch – When activated will turn on
control panel light.
3. 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.
8. Engine Speed Switch – This switch controls the speed
of the engine (low/high).
9. Diagnostic Display – This display monitors crtical engine
functions. If any abnormal conditions occur, an Active
Fault Code will be displayed.This diagnostic display can
be located inside the control box
4. Fuel Gauge - Indicates amount of diesel fuel available.
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ENGINE OPERATING PANEL
10. Warning Lamp – This lamp will illuminate when a
critical engine fault has occured.
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.
11. 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.
If the generator is to be connected to a building’s
AC power source via an automatic transfer switch
(isolation), place the switch in the AUTO position.In this
position, should an outage occur, the automatic transfer
switch (ATS) will start the generator automatically
via the generator’s auto-start contacts connected to
the ATS’s start contacts. Please refer to your ATS
installation manual for further instructions for the
correct installation of the auto-start contacts of the
generator to the ATS.
12. Emergency Stop Lamp – This lamp will illuminate
when the emergency stop button has been pressed
or a critical engine fault has occured.
13. Fuel Leak Detected Alarm Lamp – This lamp will
illuminate when a leak in the fuel tank containment
enclosure is detected.
14. . Auto START/STOP Engine Controller (ECU) —This
controller has a vertical row of
status LED's (inset), that when lit,
indicate that an engine malfunction
(fault) has been detected.When a
fault has been detected the engine
controller will evaluate the fault
and all major faults will shutdown
the generator. During cranking
cycle, the ECU will attempt to
crank the engine for 10 seconds
before disengaging.
B. Low Oil Pressure — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
C. High Coolant Temperature — Indicates the engine
temperature has exceeded 239°F (110°C).The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
D. Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
times, and has failed to start. The number of cycles
and duration are programmable. It is pre-set at 3
cycles with a 10 second duration. This is considered
a major fault.
If the engine does not engage (start) by the third
attempt, the engine will be shutdown by the engine
controller’s Over Crank Protection mode. If the engine
engages at a speed (RPM's) that is not safe, the
controller will shutdown the engine by initializing the
Over Speed Protection mode.
E. Overspeed Shutdown — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
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.
F. Engine Running — Indicates that engine is running
at a safe operating speed.
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OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
OUTPUT TERMINAL FAMILIARIZATION
The Output Terminal Panel (Figure 7) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three 120/240V output receptacles @ 50 amp
Three Circuit Breakers @ 50 amps
NOTICE
Two 120V GFCI receptacles @ 20 amp
Two GFCI Circuit Breakers @ 20 amps
Five Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O”and “Ground”are considered bonded
grounds.
Figure 7. Output Terminal Panel
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
all three receptacles is dependent on the load requirements
of the Output Terminal Lugs.
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles 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 10) 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 8) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 10. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire
Hookup Panel)
The OutputTerminalLugsareprotectedbyaplastic
face plate cover (Figure 11). 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 8. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 9) 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 11. Plastic Face Plate
(Output Terminal Lugs)
Figure 9. 120/240V Twist-Lock Auxiliary
Receptacles
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OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 12).
Make sure to read the operation manual before attempting
to connect a load to the generator.
An over current relay (Figure 13) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
To protect the output terminals from overload, a 3-pole,
175A main circuit breaker is provided.Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 13. Over Current Relay
Figure 12. Connecting Loads
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LOAD APPLICATION
SINGLE PHASE LOAD
THREE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
When calculating the power requirements for 3-phase
power use the following equation:
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.
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
WATTS = VOLTAGE x AMPERAGE
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can
burn out the appliance or tool and overheat the cable. See
Table 6.
The power factor of this generator is 0.8.SeeTable 5 below
when connecting loads.
Table 5. Power Factor By Load
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.
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
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.
0.4-0.9
Electronic devices, communication
equipment
1.0
0.8
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
Table 6. Cable Selection (60 Hz, Single Phase Operation)
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Load in Watts
Maximum Allowable Cable Length
Current
in
Amperes
At 100
Volts
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
DANGER
2.5
5
300
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.
600
1200
1800
2400
3600
4800
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.
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 41
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GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
Generator Amperage
A wide range of voltages are available to supply voltage for
many different applications.Voltages are selected by using
the voltage selector switch (Figure 14).To obtain some of
the voltages as listed in Table 7 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Table 8. Generator Maximum Amps
Rated Voltage
Maximum Amps
Voltage Selector Switch
1Ø 240/120 position (120V)
188.9 Amps (4 wire)
250 Amps x 2 (Zigzag)
Voltage Selector Switch
Voltage Selector Switch
1Ø 240/120 position (240V)
94.4 Amps (4 wire)
250A (Zigzag)
The voltage selector switch (Figure 14) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
Voltage Selector Switch
3Ø 240/139 position (240V)
204 Amps
102 Amps
Voltage Selector Switch
3Ø 480/277 position (480V)
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the 2 twist lock auxiliary receptacles.
Tables 9 and 10 show what amount of current is available
at the GFCI receptacles when the output terminals and
twist lock receptacles are in use. Be careful that your load
does not to exceed the available current capability at the
receptacles.
Figure 14. Voltage Change-Over Board
Voltage Selector Switch Locking Button
To lock the voltage selector switch, press and hold the
red button located at the bottom of the switch. While
holding the red button down, insert a pad lock into the hole
next to the button to retain it in the inward locked position.
When the lock is removed, the red button is spring loaded
and will return to its normal outward unlocked position
switch.
Table 9. 1Ø GFCI Receptacle Load Capacity
KW in Use
Twist Lock (C6369)
Available Load
Current (Amps)
GFCI Duplex
1Ø 240/120V
5-20R 120V
60.0
58.8
0 amps/receptacle
5 amps/receptacle
57.6
56.4
55.2
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Table 10. 3Ø GFCI Receptacle Load Capacity
KVA in Use
(UVWO Terminals)
Available Load
Current (Amps)
GFCI Duplex
Table 7. Voltages Available
3Ø 240/480V
5-20R 120V
UVWO Output
Terminal Lugs
Voltage Selector Switch
3-Phase 240/139V Position
Voltage Selector Switch
3-Phase 480/270V Position
0 amps/receptacle
5 amps/receptacle
85
208V
120V
220V
127V
240V
139V
416V
240V
440V
254V
480V
277V
3Ø Line-Line
80.8
1Ø Line-Neutral
10 amps/receptacle
15 amps/receptacle
20 amps/receptacle
76.7
72.5
68.4
Voltage Selector Switch Single-Phase 240/120V Position
1Ø Line-Neutral/
Line-Line
120V
Line-Neutral
240V
Line-Line
N/A
N/A
N/A
N/A
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GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 18)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 19). This process can be repeated for
terminals V and W.
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over
switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 15) to the position which produces
the required voltage (For example, for 3Ø 240V, choose
the center 3Ø 240/139V position on the voltage selector
switch).
Figure 18. AC Ammeter
Change-Over Switch
Figure 19. AC Ammeter
(Amp Reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 15. Voltage Selector Switch
240/139V 3Ø Position
NOTICE
For 3Ø 208V/1Ø,120V, place the Voltage Selector
Switch in the 3 Phase 240/139 position.
AC Voltmeter Gauge Reading
Place the ACVoltmeter Change-Over Switch (Figure 16)
in theW-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 17)
Figure 16. AC Voltmeter
Change-Over Switch
Figure 17. AC Voltmeter
Gauge
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OUTPUT TERMINAL PANEL CONNECTIONS
3. Turn the voltage regulator knob (Figure 22) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control
Knob.
Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.
Figure 22. Voltage Regulator Knob
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
3Ø-240/139 UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 23.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 20.
Figure 23. Voltage Selector Switch
3Ø-240/139V Position
Figure 20. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 24.
2. Connect the load wires to the UVWO terminals as
shown in Figure 21.
Figure 24. UVWO Terminal Lugs
3Ø-208/1Ø-120V Connections Connections
NOTICE
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 21. UVWO Terminal Lugs
3Ø-240/139V Connections
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OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 25.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 27.
Figure 25. Voltage Selector Switch
3Ø-480/277V Position
Figure 27. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 26.
2. Connect the load wires to the UVWO terminals as
shown in Figure 28.
Figure 26. UVWO Terminal Lugs
3Ø-440/254V Connections
Figure 28. UVWO Terminal Lugs
1Ø-200/100V Connections
3. Turn the voltage regulator knob (Figure 22) clockwise
to increase voltage output, turn counterclockwise
to decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
3. Turn the voltage regulator knob (Figure 22) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight.The possibility of arcing
exists, that could cause a fire.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 45
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INSPECTION/SETUP
CIRCUIT BREAKERS
FUEL CHECK
DANGER
To protect the generator from an overload, a 3-pole, 400
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload.Three 50 amp
load circuit breakers have also been provided to protect the
auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Fuel spillage on a hot engine can cause
a fire or explosion.If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refilling the Fuel System
LUBRICATION OIL
CAUTION
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 29) on the dipstick. See Table 11 for
proper selection of engine oil.
ONLY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank located inside
the generator and may also be equipped with an trailer
mounted fuel tank (Figure 30). ALWAYS fill the fuel tanks
with clean fresh #2 diesel fuel. DO NOT fill the fuel tanks
beyond their capacities.
Figure 29. Engine Oil Dipstick
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.
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the
oil drain plug, and refill with the specified amount of oil as
outlined in the John Deere Engine Owner’s Manual. Oil
should be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
Table 11. Recommended Motor Oil
Figure 30. Internal Fuel Tank System
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INSPECTION/SETUP
2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel
cap and fill tank (Figure 32).
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. LevelTanks — 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 31).
CAUTION
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 32. 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 33).
Figure 31. Only Fill on Level Ground
Figure 33. Full Fuel Tank
NOTICE
CAUTION
ONLY use #2 diesel fuel when refueling.
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 34).
Figure 34. Fuel Expansion
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INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
CLEANING THE RADIATOR
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
John Deere recommends John Deere antifreeze/summer
coolant for use in their 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.
AIR CLEANER
WARNING
Periodic cleaning/replacement is necessary. Inspect it
in accordance with the John Deere Engine Owner’s
Manual.
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Deere Engine Owner’s Manual.
Day-to-day addition of coolant is done from the recovery
tank.When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities.Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 35) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
3.70 gal (14 liters)
2 quarts (1.9 liters)
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Figure 35. Fan Belt Tension
CAUTION
Table 13. Anti-Freeze Operating Temperatures
NEVER place hands near the belts or fan
while the generator set is running.
Vol %
Anti-
Freeze
Freezing Point
Boiling Point
°C
°F
°C
°F
50
-37
-34
108
226
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
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INSPECTION/SETUP
When connecting battery do the following:
BATTERY
1. NEVER connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
DO NOT over fill. Check to see whether the battery
cables are loose. Poor contact may result in poor starting
or malfunctions. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur.Pay close attention to
the polarity of the battery when connecting the battery.
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.
CAUTION
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 36) 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
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion 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.
Figure 36. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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GENERATOR START-UP PROCEDURE (MANUAL MODE)
BEFORE STARTING
STARTING
1. Place the voltage selector switch in the desired
voltage position (Figure 39)..
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
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 37) in the OFF position prior to starting the
engine.
Figure 39. Voltage Selector Switch
STARTING (MANUAL)
1. Place the engine speed switch (Figure 40) in the LOW
(down) position.
Figure 40. Engine Speed Switch (Low)
Figure 37. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Place the MPEC control switch in the MANUAL
position to start the engine (Figure 41).
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 12. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Figure 41. MPEC Control Switch
(Manual Position)
3. Depending on the temperature of the coolant (cold
weather conditions), the pre-heat lamp (Figure 42) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 38).
CORRECT
INCORRECT
Figure 42. Pre-Heat Lamp
Figure 38. Engine Enclosure Doors
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GENERATOR START-UP PROCEDURE (MANUAL MODE)
4. Once the engine starts, let the engine run for 1-2
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 43) in the HIGH (up)
position.
8. If the voltage is not within the specified tolerance use
the voltage adjustment control knob (Figure 47) to
increase or decrease the desired voltage.
Figure 47. Voltage Adjust Control Knob
9. 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 43. Engine Speed Switch (High)
5. Verify that the engine running status LED on the
MPEC module (Figure 44) is lit (ON) after the engine
has started.
Figure 48. Ammeter (No Load)
Figure 44. Engine Running (LED ON)
10. The engine oil pressure gauge (Figure 49) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
6. The generator’s frequency meter (Figure 45) should be
displaying the 50 cycle output frequency in HERTZ.
Figure 49. Oil Pressure Gauge
Figure 45. Frequency Meter
11. The coolant temperature gauge (Figure 50) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
7. The generator’s AC-voltmeter (Figure 46) will display
the generator’s output in VOLTS..
Figure 50. Coolant Temperature Gauge
Figure 46. Frequency Meter
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GENERATOR START-UP PROCEDURE (MANUAL MODE)
12. The tachometer gauge (Figure 51) will indicate the
speed of the engine when the generator is operating.
STARTING (AUTO MODE)
DANGER
Under normal operating conditions this speed is
approximately 1800 RPM’s.
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 51. Engine Tachometer Gauge
13. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 52).
CAUTION
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.
NOTICE
When the generator is set in the AUTO mode, the
generator will automatically start in the event of
commercial power falling below a prescribed level
by means of a contact closure that is generated
automatically by a transfer switch.
Figure 52. Main, Aux. and GFCI
Circuit Breakers (ON)
14. 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.
WARNING
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.
CAUTION
Figure 53. Ammeter (Load)
The engine speed switch must be set to the “High”
position when running in the auto-start mode. Failing
to set the switch in the proper position can result in
damage to your generator when it turns on.
15. The generator will run until manually stopped or an
abnormal condition occurs.
WARNING
NOTICE
NEVER stop the engine suddenly except in an
emergency.
When the MPEC control switch is placed in the AUTO
position, the engine glow plugs will be warmed and the
engine will start automatically.
When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
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GENERATOR SHUT-DOWN PROCEDURES
NORMAL SHUTDOWN PROCEDURE
1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.
To shutdown the generator, use the following procedure:
2. Place the engine speed switch (Figure 54) in the
HIGH position
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 56 to the OFF position..
Figure 54. Engine Speed Switch (High)
3. Place the MPEC Control Switch (Figure 55) in the
AUTO position.
Figure 56. Main, GFCI and Load
Circuit Breakers Off
Figure 55. MPEC Control Switch (AUTO)
2. Place the engine speed switch (Figure 57) in the “LOW”
(down) position..
4. Continue operating the generator as outlined in the
Manual Start-up procedure (start at step 5)
Figure 57. Ignition Switch (Normal)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 58) to the
OFF/RESET position.
Figure 58. MPEC Control Switch (Off/Reset)
5. Verify that all status LEDs on the MPEC display are
OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.
EMERGENCY SHUTDOWN PROCEDURE
1. Place the MPEC Control Switch (Figure 58) in the
OFF/RESET position.
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MAINTENANCE
10 Hrs
DAILY
1000
Hrs
Table 14. Inspection/Maintenance
250 Hrs 500 Hrs
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
Replace Engine Oil and Filter * 1
Clean Air Filter
X
X
Engine
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
X
Generator
Check Rotor Rear Support Bearing
Replace engine oil and filter at 100 hours, first time only.
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
3
*
4
*
with no sags or dips that could collect moisture and/or oil.
GENERAL INSPECTION
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 14 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 59)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Figure 59. Air Cleaner/Indicator
NOTICE
Air Cleaner with Dust Indicator
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
This indicator (Figure 59) 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.
PAGE 54 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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MAINTENANCE
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result.This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
FUEL TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
FUEL ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Removing Water from the Fuel Tank
FuelTank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
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.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
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 diesel fuel.
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.
Cleaning Inside the Fuel Tank
Vent any air
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 60) wash out any deposits
or debris that have accumulated inside the fuel tank.
AIR REMOVAL
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel,
or after disassembling the fuel system, bleed the system
according to the following procedure. See the JOHN
DEERE Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Figure 60. Fuel Tank Cleaning
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 55
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MAINTENANCE
CHECK OIL LEVEL
RADIATOR CLEANING
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 29.
The radiator (Figure 61) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
Replacing Oil Filter
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
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.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
Figure 61. Radiator Cleaning
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.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Drain the fuel tank completely.Treat with a fuel stabilizer
if necessary.
Tighten both cocks and replace the overflow tank.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Replace with coolant as recommended by the engine
manufacturer.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Close radiator cap tightly.
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.
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.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
PAGE 56 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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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.
TRAILER MAINTENANCE
This section is intended to provide the user with generic
trailer service and maintenance information. The service
and maintenance guidelines referenced in this section refer
to a wide range of trailers.
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.
11. Tire Rim — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
12. Lug Nuts — Used to secure the wheel to the wheel
hub. Always use a torque wrench to tighten down
the lug nuts. See Table 18 and Figure 64 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
transporting equipment.
13. Axle — Indicates the maximum weight the axle can
support in pounds, and the diameter of the axle
expressed in inches. Please note that some trailers
have a double axle.This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
2. Braking System — System employed in stopping
the trailer.Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
3. GVWR — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
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
on a particular trailer.
7. Coupler — Type of hitch used on the trailer for
towing.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 57
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TRAILER MAINTENANCE
BRAKES
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of
operation.This will allow the brake shoes and drums to seat
properly.After the first 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Hydraulic surge brakes (Figure 62) should not require any
special attention with the exception of routine maintenance
such as shoe and lining replacement. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 62 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 15 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
Figure 62. Hydraulic Brake Components
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
Actuator
Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
or push of the trailer toward the tow vehicle automatically
synchronizes the trailer brakes with the tow vehicle brakes.
As the trailer pushes against the tow vehicle the actuator
telescopes together and applies force to the master
cylinder, supplying hydraulic pressure to the trailer brakes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
Periodically check and test the surge “actuator” to make sure
that it is functioning correctly. Never use an undersize actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Repair or replace.
Reburnish or replace.
Correct weight.
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?
Replace components.
Locking Brakes
Noisy Brakes
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Install new shoes and
linings.
Brake lining thickness incorrect or
not adjusted correctly?
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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TRAILER MAINTENANCE
TIRES/WHEELS/LUG NUTS
Suspension
Tires and wheels are a very important and critical
components of the trailer.When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
The leaf suspension springs and associated components
(Figure 63) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately.Torqued suspension components
as detailed in Table 17.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION
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 63. Major Suspension Components
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire
life. Pressure should be checked cold before operation DO
NOT bleed air from tires when they are hot!.Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 17. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
Min-30 Max-35
Min-45 Max-60
Min-45 Max-60
3/8" U-Bolt
7/16" U-Bolt
1/2" U-Bolt
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
Shackle Bolt
Spring Eye Bolt
Table 16. Tire Wear Troubleshooting
provided to retain nut-bolt assembly.
Wear Pattern
Cause
Solution
Shoulder Type
Shackle Bolt
Min-30 Max-50
Adjust pressure to particular
load per tire manufacturer.
Center Wear Over inflation.
Edge Wear Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Loss of camber
Side Wear
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup and Avoid sudden stops when
tire skidding. possible and adjust brakes.
Flat Spots
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 59
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TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 64). DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
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 64. Wheel Lug Nuts
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
PAGE 60 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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TRAILER WIRING DIAGRAM
Figure 65. Trailer/Towing Vehicle Wiring Diagram
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 61
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GENERATOR WIRING DIAGRAM
Figure 66. Generator Wiring Diagram
PAGE 62 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENGINE WIRING DIAGRAM
Figure 67. Engine Wiring Diagram
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 63
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TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Table 19. Generator Troubleshooting
Symptom
Possible Problem
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
Solution
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Is engine speed correct?
Check for approximately 17.3 ohms across J & K on CN1
Turn engine throttle lever to “High”.
Low Voltage Output
High Voltage Output
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated? Confirm load requirement and replace.
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TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
useTable 20 (Engine ControllerTroubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
Table 20. Engine Controller Troubleshooting (MPEC)
Symptom
Possible Problem
Low oil level?
Solution
Fill oil level.
Oil pressure sending unit failure?
Time delay malfunction 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.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulating through radiator? Clean/repair radiator grill.
Doors open?
Close doors.
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
Replace thermostat.
Clean all air intakes.
Replace temperature switch.
Fill fuel level.
High coolant temperature
light is on.
Generator being overloaded?
Thermostat failure?
Air intake blocked?
Temperature switch failure
No or low fuel?
Overcrank light is on.
Overspeed light is on.
Loss of MPU light(s) or on.
Controller needs to be calibrated?
RPM engine speed too high?
Refer to dealer.
Adjust RPM.
Governor actuator needs to be adjusted? Adjust governor actuator.
Governor controller needs to be adjusted? Adjust governor controller.
Engine controller needs to be calibrated? Refer to dealer.
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Adjust magnetic pick up.
Clean magnetic pick up.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 65
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
1
2%
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
WASHER, 3/8 IN....1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items.Examples include battery cables, shims,
and certain washers and nuts.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
“Not Sold Separately”— Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
PAGE 66 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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SUGGESTED SPARE PARTS
DCA85USJ2 WHISPERWATT GENERATOR WITH
JOHN DEERE4045HF285 DIESEL ENGINE
1 to 3 units
QTY. P/N
DESCRIPTION
5............RE504836.............CARTRIDGE , OIL FILTER
5............RE529643.............FILTER, FUEL, CARTRIDGE PRIMARY
5............RE522878.............FILTER, FUEL, CARTRIDGE FINAL
3............0602046365..........ELEMENT, AIR
1............R135680...............BELT, FAN
1............M3310501803.......RADIATOR HOSE, UPPER
1............M3310501903.......RADIATOR HOSE, LOWER
1............RE503883.............SENSOR, WATER TEMP. (ENGINE SIDE)
1............51M7041...............O-RING, WATER TEMP. (ENGINE SIDE)
1............RE167207.............SWITCH, OIL PRESSURE (ENGINE SIDE)
1............0601870440..........CIRCUIT BREAKER, 1P, 20 AMP
1............0601870441..........CIRCUIT BREAKER, 2P, 50 AMP
1............0601802149..........FUSE, 10 AMP
1............0601806653..........FUSE, 20 AMP
1............0601820602..........AUTOMATIC VOLTAGE REGULATOR
1............0602122272..........UNIT, OIL PRESSURE
1............0602123263..........UNIT, WATER TEMPERATURE
1............RE52722...............SENSOR, COOLANT, TEMPERATURE (ENGINE SIDE)
1............51M7041...............O-RING, COOLANT TEMP. (ENGINE SIDE)
1............AT85174 ...............SWITCH, OIL PRESSURE (ENGINE SIDE)
1............RE525016.............THERMOCOUPLE
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 67
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GENERATOR ASSY.
PAGE 68 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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GENERATOR ASSY.
NO.
1
PART NO.
B6110100102
PART NAME
ROTOR ASSY..............................1 ...........INCLUDES ITEMS W/#
QTY.
REMARKS
1-1#
1-2#
1-3#
1-4#
1-5#
1-6#
1-7#
1-8#
1-9#
1-10#
1-11#
1-12#
1-13#
1-14#
1-15#
1-16#
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
FIELD ASSY
FAN
HEX HEAD BOLT
COUPLING DISK
1
1
8
5
8101070033
0012810035
8101611004
8101015003
0012110030
0042510000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906311
M2163400003
0343204170
0043604000
B6130000303
0845041804
8101315202
8101340013
0012110070
0042610000
0041210000
0017110035
8101310014
8131312014
0017106012
8101331003
0017106012
8101333003
0340406040
0041206000
0012810030
8111332014
0340406040
0041206000
0600815000
0605000010
0030012000
0040012000
0041212000
0070506306
BALANCING PLATE.....................1 ...........PURCHASE ITEMS 1-1THRU 1-15 AS A SET
HEX HEAD BOLT
WASHER, LOCK
SET PLATE, RECTIFIER .............1 ...........PURCHASE ITEMS 1-1THRU 1-15 AS A SET
RECTIFIER
SURGE ABSORBER
INSULATOR WASHER
INSULATOR WASHER
HEX HEAD BOLT
WASHER, LOCK
BALANCING WEIGHT KIT
BEARING
COUPLING RING
HEX HEAD BOLT
WASHER, LOCK
STATOR ASSY
8
8
2
1
1
1
4
4
1
1
1
8
8
1
2
1
1
4
4
4
6
1
1
6
1
4
1
1
1
12
1
1
1
1
2
2
2
2
1
GROMMET
END BRACKET
FIELD ASSY EXCITER
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
COVER, BEARING
GASKET, BEARING
HEX HEAD BOLT
COVER, END BRACKET
HEX HEAD BOLT
COVER, END BRACKET
HEX HEAD BOLT
WASHER, FLAT
HEX HEAD BOLT
COVER, FAN
HEX HEAD BOLT
WASHER, FLAT
NUT
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
WASHER, FLAT
BEARING
27A
27B
28
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 69
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CONTROL BOX ASSY.
PAGE 70 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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CONTROL BOX ASSY.
NO.
1
1
1-1
1-2
1-3
2
2
2-1
PART NO.
PART NAME
QTY.
REMARKS
M2213001702
M2213001712
0330000180
0330000280
0330000325
0601808822
0601807522
0026602100
CONTROL BOX ..........................................1 ................S/N 8400985 AND BELOW
CONTROL BOX ..........................................1 ................S/N 8400986 AND ABOVE
EDGING
EDGING
EDGING
CIRCUIT BREAKER, 250A .........................1 ................S/N 8400985 AND BELOW
CIRCUIT BREAKER, 250A .........................1 ................S/N 8400986 AND ABOVE
MACHINE SCREW .....................................6 ................S/N 8400985 AND BELOW
WASHER, LOCK.........................................6 ................S/N 8400985 AND BELOW
MACHINE SCREW .....................................4 ................S/N 8400985 AND BELOW
RELAY UNIT
MACHINE SCREW
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
CURRENT TRANSFORMER
MACHINE SCREW
OVER CURRENT RELAY
OVER CURRENT RELAY
MACHINE SCREW
2
1
2
2-1A 0044102000
3
4
5
6
7
8
9
0021005080
0601823863
0027104016
0601820602
0027105016
0601801124
0027106020
0601820849
0601820848
0027104020
0207004000
LY2DC12V
2
4
1
4
3
6
1
1
2
2
10
11
12
12A
13
13A
13B
14
15
15
16
17
17
18
19
19A
19B
20
21
22
23
23A
24
25
25A
25B
26
27
28
29
30
HEX NUT
RELAY.........................................................1 ................REPLACES P/N 0601823768
BASE...........................................................1 ................REPLACES P/N 0601823109
CLIP ............................................................2 ................REPLACES P/N 0601824400
PTF08A
PTCA1
0027104020
M4260600304
M4260600314
0016908020
0602120690
0602120691
0601831330
0601813977
0601812891
0601812890
0027103015
M3260500404
0016906016
0602202592
0030006000
0027106016
LY20DC12V
PTF08A
MACHINE SCREW
2
BRACKET, DIAGNOSTIC GAUGE..............1 ................S/N 8400900 AND BELOW
BRACKET, DIAGNOSTIC GAUGE..............1 ................S/N 8400901 AND ABOVE
HEX HEAD BOLT
POWER VIEW.............................................1 ................S/N 8400900 AND BELOW
DIAGNOSTIC GAUGE ................................1 ................S/N 8400901 AND ABOVE
DIAGNOSTIC SWITCH
RECEPTACLE
DUST CAP
STRAIN RELIEF
MACHINE SCREW
SET PANEL, ELECTRIC PARTS
HEX HEAD BOLT
STARTER RELAY
HEX NUT
2
1
1
1
1
2
1
4
1
2
2
MACHINE SCREW
RELAY.........................................................1 ................REPLACES P/N 0601827656
BASE...........................................................1 ................REPLACES P/N 0601823109
CLIP ............................................................2 ................REPLACES P/N 0601824400
MACHINE SCREW
RECTIFIER
MACHINE SCREW
BRACKET, RESISTOR UNIT
HEX HEAD BOLT
PYCA1
0027104020
0601823240
0027104020
M4260600404
0016906016
2
2
2
1
2
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 71
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CONTROL BOX ASSY. (CONTINUED)
PAGE 72 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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CONTROL BOX ASSY. (CONTINUED)
NO.
31
32
33
33A
33B
34
35
36
PART NO.
PART NAME
RESISTOR UNIT
MACHINE SCREW
HOLDER, FUSE
QTY.
1
1
1
1
1
2
1
8
1
1
1
1
1
4
4
4
REMARKS
M4266600004
0027105016
0601802218
0601806653
0601802149
0027103020
M3213500704
0016906016
M2270100204
M2550001404
M2550001504
M3213602704
M3213602804
0027104035
0207004000
0027104016
0207004000
0016906016
M2213603104
FUSE (RIGHT SIDE), 20A
FUSE ( CENTER), 10A
MACHINE SCREW
CONTROL BOX COVER
HEX HEAD BOLT
SELECTOR SWITCH
DECAL : SELECTOR SWITCH NO
DECAL : SELECTOR SWITCH NO
SWITCH BRACKET
SWITCH BRACKET
MACHINE SCREW
HEX NUT
37
37A
37B
38
39
40
40A
41
41A
42
MACHINE SCREW
HEX NUT
HEX HEAD BOLT
4
4
1
43
SWITCH COVER
43-1 0317700180
WEATHER STRIP
SWITCH COVER
HEX HEAD BOLT
HEX HEAD BOLT
TOOTHED WASHER
1
1
10
10
1
44
45
46
46A
47
47
48
49
50
51
52
53
56
56A
57
58
58A
59
60
61
62
63
64
65
66
67
M2213603004
0016906016
0016908020
0040508000
M2223001203
M2223001213
0601807641
0601808988
0601801040
0601806859
0601801041
0601840073
0021004040
0207004000
0601831340
0602103092
0601810245
0602120096
0602122093
0602123092
0602121081
0602125090
0601810141
0601831330
0601831395
M122310004
CONTROL PANEL ......................................1 ................S/N 8400985 AND BELOW
CONTROL PANEL ......................................1 ................S/N 8400986 AND ABOVE
FREQUENCY METER, 45~65Hz 240V
AC AMMETER, 0~200A/400A:5A
CHANGE - OVER SWITCH, AMMETER
AC VOLTMETER, 0~600V
CHANGE - OVER SW, VOLTMETER
RHEOSTAT, 2W 1k OHM
MACHINE SCREW
HEX NUT
SWITCH
ALARM LAMP
BULB, DC18V
TACHOMETER
1
1
1
1
1
1
2
2
1
4
4
1
1
1
1
1
1
1
1
1
OIL PRESSURE GAUGE
WATER TEMPERATURE GAUGE
CHARGING AMMETER
FUEL GAUGE
PANEL LIGHT
SWITCH, PANEL LIGHT
SWITCH, ENGINE SPEED
STOPPER
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 73
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CONTROL BOX ASSY. (CONTINUED)
PAGE 74 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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CONTROL BOX ASSY. (CONTINUED)
NO.
68
69
70
71
72
73
74
75
76
76
77
PART NO.
PART NAME
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
QTY.
REMARKS
M3223100004
0027105010
0027105010
M9220100004
0080200007
0602122272
0602123263
0602012345
M2246702204
M2246702214
M2357201902
1
4
4
2
2
1
1
1
SNAP RING
UNIT, OIL PRESSURE
UNIT, WATER TEMPERATURE
O-RING
WIRE HARNESS, GENERATOR ................1 ................S/N 8400985 AND BELOW
WIRE HARNESS, GENERATOR ................1 ................S/N 8400986 AND ABOVE
WIRE HARNESS, ENGINE
1
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 75
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ENGINE AND RADIATOR ASSY.
PAGE 76 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENGINE AND RADIATOR ASSY.
NO.
1
PART NO.
PART NAME
ENGINE, JOHN DEERE 4045HF285
FAN BELT....................................................1 ................REPLACES P/N 0602015233
CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041292
CARTRIDGE, PRIMARY FUEL FILTER......1 ................REPLACES P/N 0602042596
CARTRIDGE, FINAL FUEL FILTER............1 ................REPLACES P/N 0602042597
QTY.
1
REMARKS
M2923200094
R135680
RE504836
RE529643
RE522878
0602060008
0602061000
0012110095
0042510000
M2303200303
0010312030
0040012000
0605000009
0030012000
0040012000
C0923200124
1A
1-1
1-2
1-3
2
3
4
5
6
7
8
9
10
11
12
BLOWER FAN
FAN SPACER
1
1
4
4
2
6
6
2
2
2
1
1
2
1
1
1
1
3
1
1
4
2
8
1
1
1
1
2
1
1
1
2
1
1
HEX HEAD BOLT
WASHER, LOCK
ENGINE FOOT
HEX HEAD BOLT
WASHER, LOCK
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
RADIATOR
CAP, RADIATOR
HEX HEAD BOLT
PLUG
12-1 0602011029
13
14
15
16
17
18
19
20
21
22
23
24
24A
25
26
27
28
29
30
31
32
33
34
34
35
35
36
36
37
37
0016910025
M9200100904
0150000016
M3310501803
M3310501903
0605515148
0605515147
M2313300203
0016910025
0601822794
0016910025
0602046582
0602046365
0602040651
0602040554
0016908030
M2373101703
M2373101803
0605515146
0605515197
0191600530
0605515149
0602022563
0602022586
0602022561
0602022579
0603306590
0603306597
0603300285
0603300286
O-RING
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
HOSE BAND
FAN BRACKET
HEX HEAD BOLT
FAN MOTOR
HEX HEAD BOLT
AIR CLEANER
ELEMENT, AIR CLEANER
INDICATOR, AIR CLEANER
AIR CLEANER BAND
HEX HEAD BOLT
HOSE, AIR CLEANER
HOSE, AIR CLEANER
HOSE BAND
HOSE BAND
BLOWBY HOSE
HOSE BAND
ADAPTER....................................................1 ................S/N 8400995 AND BELOW
ADAPTER....................................................1 ................S/N 8400996 AND ABOVE
90 DEGREE ELBOW ..................................1 ................S/N 8400995 AND BELOW
90 DEGREE ELBOW ..................................1 ................S/N 8400996 AND ABOVE
CONNECTOR .............................................1 ................S/N 8400995 AND BELOW
CONNECTOR .............................................1 ................S/N 8400996 AND ABOVE
LOCKNUT ...................................................1 ................S/N 8400995 AND BELOW
LOCKNUT ...................................................1 ................S/N 8400996 AND ABOVE
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 77
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ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 78 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENGINE AND RADIATOR ASSY. (CONTINUED)
NO.
38
38
39
39
40
40
41
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
67A
68
69
70
71
72
73
74
75
76
77
78
PART NO.
PART NAME
QTY.
REMARKS
0605511395
0605511399
0603306395
0603306399
0602021070
0602021071
0269200700
0379500700
M9300000103
0602010900
M3316100303
0016908020
0199102200
0193600700
0193601000
0605515106
0602015001
M2310200802
0017110020
0016906016
M2310502603
M2310502503
0605515208
0605515215
M2310201004
0016906016
M2310303703
M2310303803
0016906016
M2310303803
0016906016
M3260600104
0017110020
0602202592
0030006000
0027106016
0602017090
M9200101004
0150000016
RE503883
VALVE .........................................................1 ................S/N 8400995 AND BELOW
VALVE .........................................................1 ................S/N 8400996 AND ABOVE
HOSE JOINT...............................................1 ................S/N 8400995 AND BELOW
HOSE JOINT...............................................1 ................S/N 8400996 AND ABOVE
CAP.............................................................1 ................S/N 8400995 AND BELOW
CAP.............................................................1 ................S/N 8400996 AND ABOVE
DRAIN HOSE..............................................1 ................S/N 8400995 AND BELOW
DRAIN HOSE..............................................1 ................S/N 8400996 AND ABOVE
RESERVE TANK
1
1
1
3
1
1
1
3
1
1
8
10
1
1
2
2
1
8
1
1
8
1
4
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HEX HEAD BOLT
HOSE
HOSE
HOSE
HOSE BAND
INTER COOLER
BRACKET, INTER COOLER
HEX HEAD BOLT
HEX HEAD BOLT
INTER COOLER HOSE
INTER COOLER HOSE
HOSE BAND
HOSE BAND
BRACKET, FAN SHROUD
HEX HEAD BOLT
FAN SHROUD
FAN SHROUD
HEX HEAD BOLT
FAN GUARD
HEX HEAD BOLT
RELAY BRACKET
HEX HEAD BOLT
RELAY
HEX NUT
MACHINE SCREW
DRAIN VALVE
ADAPTER
O-RING
SENSOR WATER TEMPERATURE
O-RING SENSOR WATER TEMP.
SENSOR , COOLANT TEMPERATURE
O-RING SENSOR WATER TEMP.
SWITCH, OIL PRESSURE
THERMOCOUPLE
O-RING SENSOR WATER TEMP.
51M7041
RE52722
51M7041
AT85174
RE525016
51M7041
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 79
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OUTPUT TERMINAL ASSY.
PAGE 80 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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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
M3236100803
M3236100404
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
M9220100804
0040006000
0041206000
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX NUT
10
15
20
5
1
1
2
4
4
4
4
4
2
2
2
2
4
1
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
TERMINAL COVER
OUTPUT WINDOW
HINGE
MACHINE SCREW
HEX NUT
WASHER, FLAT
MACHINE SCREW
HEX NUT
9
10
11
11A
11B
12
12A
13
13A
13B
SET SCREW
WASHER, LOCK
WASHER, FLAT
RETAINING RING
HEX HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER 1
HEX HEAD BOLT
TERMINAL
MACHINE SCREW
BLIND PLUG
MACHINE SCREW
CIRCUIT BREAKER, 1P 20A
CIRCUIT BREAKER, 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX HEAD BOLT
13C 0080200005
14
15
16
17
18
19
20
21
22
23
24
0016906016
M3236400004
M3236300004
0016906020
0601815194
0027104016
0603306775
0027104016
0601870440
0601870441
M1260700504
6
1
2
2
4
2
3
1
2
2
2
24-1 0222100100
25
26
27
27
28
28A
29
30
31
32
33
34
35
36
37
38
0016906020
0601812598
0601812538
0601814014
0027104016
0207004000
M3236400204
0016906016
M2236100903
0010112045
0041212000
M9310200004
0030012000
M4236100604
M4236400304
0016906016
RECEPTACLE, 125V 20AX2
RECEPTACLE, 250V 50A, CS6369............3 ................S/N 8400995 AND BELOW
RECEPTACLE, 250V 50A, CS6369L..........3 ................S/N 8400996 AND ABOVE
MACHINE SCREW
HEX NUT
COVER
HEX HEAD BOLT
TERMINAL COVER
HEX HEAD BOLT
WASHER, FLAT
STAY RUBBER
HEX NUT
10
10
1
8
1
2
2
2
2
COVER
BRACKET
HEX HEAD BOLT
1
1
2
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 81
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BATTERY ASSY.
PAGE 82 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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BATTERY ASSY.
NO.
1
2
3
4
PART NO.
PART NAME
BATTERY
QTY.
REMARKS
0602220199
M9310500014
M9103000304
0602220920
M4346900304
M2346900304
1
1
1
2
1
1
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
BATTERY CABLE
BATTERY CABLE
5
6
7
CABLE.........................................................1 ................PURCHASE LOCALLY
8
8A
9
0017112025
0040512000
0040520000
HEX HEAD BOLT
TOOTHED WASHER
TOOTHED WASHER
1
1
1
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 83
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MUFFLER ASSY.
PAGE 84 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
MUFFLER
HEX HEAD BOLT
EXHAUST PIPE
GASKET
HEX HEAD BOLT
CLAMP
COVER, EXHAUST PIPE
BRACKET, EXHAUST PIPE
HEX HEAD BOLT
U BOLT
QTY.
REMARKS
M2330101303
0017112030
M2333001603
M2333200204
0017110050
0602325066
M3330401104
M3330401003
0016908020
0602326061
1
4
1
1
4
1
1
1
4
1
9
10
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 85
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FUEL TANK ASSY.
PAGE 86 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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FUEL TANK ASSY.
NO.
1
1-1
1-2
PART NO.
PART NAME
FUEL TANK
FUEL TANK CAP
FUEL SENDER UNIT
GASKET
QTY.
1
1
1
1
REMARKS
M2363000902
0605505070
0605501073
1-2A 0605516090
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
M2363200404
M2363200904
M9310500104
0016908020
0207008000
0222101000
0191302140
0605515109
0602042601
0191301000
0191300700
0605515109
0605511190
0605512190
0605512191
TANK BAND
TANK BAND
SUPPORTER SHEET
HEX HEAD BOLT
HEX NUT
TANK SHEET
VENT HOSE
HOSE BAND
RETURN PIPE
SUCTION HOSE
RETURN HOSE
HOSE BAND
3
3
6
6
6
5
1
2
19
1
1
4
1
PICKUP ELBOW
HOSE JOINT
HOSE JOINT, 1/4-18 NPT
1
1
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 87
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ENCLOSURE (1) ASSY.
PAGE 88 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENCLOSURE (1) ASSY.
NO.
1
2
3
4
5
5A
6
6A
7
8
PART NO.
PART NAME
BASE
ENVIRONMENTAL TANK
HEX HEAD BOLT
PLUG
FRONT FRAME
ACOUSTIC SHEET
FRONT FRAME
ACOUSTIC SHEET
GROMMET
HEX HEAD BOLT
HEX HEAD BOLT
HOSE COVER
HEX HEAD BOLT
HOSE COVER
HEX HEAD BOLT
BRACKET
HEX HEAD BOLT
DUCT COVER
HEX HEAD BOLT
SHROUD BRACKET
HEX HEAD BOLT
DISCHARGE GUIDE
ACOUSTIC SHEET
HEX HEAD BOLT
COVER, FRONT FRAME
ACOUSTIC SHEET
FRONT LOUVER
HEX HEAD BOLT
HEX HEAD BOLT
HEX HEAD BOLT
CENTER FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
ROOF PANEL
QTY.
1
1
12
1
1
1
1
1
1
27
6
1
7
1
8
1
6
2
14
1
11
1
1
4
1
1
1
6
4
4
1
1
4
4
4
8
REMARKS
M2413002202
M2363300703
0016910030
0603306797
M2423002102
M2493108903
M2423002202
M2493108903
0601851739
0015908020
0016910025
M3131400404
0016906020
M3131400503
0015905020
M3423500104
0016906016
M3423200704
0016906020
M2310200904
0016906016
M2423300704
M2493109004
0016908020
M2423203203
M2493109103
M2423203303
0019206016
0019208020
0016908020
M2433001202
M2493200504
0010114040
0030014000
0040014000
9
10
11
12
13
14
15
16
17
18
19
20
20A
21
22
22A
23
24
25
26
27
27A
28
28A
28B
28C 0041214000
29
29A
29B
29C 004122000
30
30A
31
31A
32
0010120050
0030020000
0040014000
4
4
4
8
1
1
1
1
M2493505204
M2493505204
M2463200102
M2493506203
M3463200704
0016906016
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
BACK PLATE
HEX HEAD BOLT
2
12
33
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 89
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ENCLOSURE (1) ASSY. (CONTINUED)
PAGE 90 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENCLOSURE (1) ASSY. (CONTINUED)
NO.
34
34A
35
36
37
38
38A
39
40
41
42
43
44
45
PART NO.
PART NAME
DUCT
ACOUSTIC SHEET
HEX HEAD BOLT
DUCT COVER
QTY.
1
1
10
1
6
1
1
51
8
1
4
1
2
1
1
1
1
2
REMARKS
M2463200603
M2493502104
0016908020
M2463400203
0016908020
M2423200814
M2493102604
0019208020
0019210025
M331060004
0019208020
M2483100504
0016908020
0016908020
0040508000
0605503062
M1414800104
0016908020
HEX HEAD BOLT
OVER COVER, FRONT FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
HEX HEAD BOLT
COVER, RADIATOR CAP
HEX HEAD BOLT
COVER, EXHAUST PIPE
HEX HEAD BOLT
HEX HEAD BOLT
TOOTHED WASHER
FUEL LEAK DETECTED SWITCH
BRACKET
45A
46
47
48
HEX HEAD BOLT
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 91
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ENCLOSURE (2) ASSY.
PAGE 92 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENCLOSURE (2) ASSY.
NO.
1
1A
2
3
4
4A
4-1
4-2
4-3
5
6
6A
7
PART NO.
PART NAME
QTY.
REMARKS
M3443001902
M3493308603
M3443002004
0016908020
M2443400003
M2493305604
0314501350
0330000180
0330000325
0016908020
M3443002103
M3493308804
M3443002203
M3493308804
0016908020
0016908020
0016910025
M3443301803
M3493308704
0019208020
0016908020
M3443200803
M3443600304
0207306000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0019208020
M2453202002
M2493410204
0019108065
0042308000
0042408000
0016910025
M2453003303
M249341004
M2453003403
M2493410004
M2453001503
M2493404504
M2453003503
M2493410104
REAR FRAME
ACOUSTIC SHEET
DUCT
HEX HEAD BOLT
PANEL, REAR FRAME
ACOUSTIC SHEET
RUBBER SEAL
EDGING
EDGING
HEX HEAD BOLT
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX HEAD BOLT
HEXHEAD BOLT
HEX HEAD BOLT
COVER, REAR FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
HEX HEAD BOLT
DOOR, REAR FRAME
WINDOW PLATE
HEX NUT
WASHER, FLAT
DOOR HANDLE ASSY
MACHINE SCREW
HEX NUT
HINGE
WASHER
1
1
2
6
1
1
1
1
1
6
1
1
1
1
6
6
4
1
2
4
4
1
1
8
8
1
4
4
2
2
3
1
1
4
4
4
2
1
1
1
1
1
1
1
1
7A
8
9
10
11
11A
12
13
14
15
16
16A
17
18
18A
19
20
21
22
22A
23
23A
23B
24
25
25A
26
26A
27
27A
28
28A
HEX HEAD BOLT
SPLASHER PANEL
ACOUSTIC SHEET
HEX BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 93
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ENCLOSURE (2) ASSY. (CONTINUED)
PAGE 94 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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ENCLOSURE (2) ASSY. (CONTINUED)
NO.
29
29A
30
30A
31
32
33
34
35
36
37
38
39
PART NO.
PART NAME
DOOR HANDLE ASSY
RUBBER SEAL
MACHINE SCREW
HEX NUT
HINGE
HINGE
WASHER
HEX HEAD BOLT
STOPPER
QTY.
4
4
16
16
6
REMARKS
M9113000002
C9312500004
0021806016
0030006000
M9110100804
M9110100904
M9116100004
0019208020
0601850097
0027208025
M9310000004
0600800320
0021806016
5
11
26
8
8
13
1
MACHINE SCREW
CAP
MANUAL PAK, 9000-07
MACHINE SCREW
4
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 95
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RUBBER SEALS ASSY.
PAGE 96 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
REMARKS
0229201240
0229201130
0314502550
0229200125
0228901165
0228900850
0228901105
0228900565
0228900820
0228900505
0229201090
0229201335
0228800970
0228800745
0229201090
0228100630
0229401080
0228800565
0228801080
0228800545
0228100370
0228100640
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
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
1
1
4
3
4
3
1
4
1
1
2
1
1
1
2
1
1
1
1
2
2
9
10
11
12
13
14
15
16
17
18
19
20
21
22
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 97
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NAMEPLATE AND DECALS ASSY.
PAGE 98 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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NAMEPLATE AND DECALS ASSY.
NO. PART NO.
1
PART NAME
QTY.
REMARKS
M1550000204
DECAL : NOTE........................................................ 1............M15000020
DECAL : AUXULIARY OUTPUT.............................. 1............M15000220
DECAL : GEN. CTRL. S/N 8400985 AND BELOW . 1............M25000260
DECAL : GEN. CTRL. S/N 8400986 AND ABOVE.. 1............M25000261
DECAL : ENGINE OPERATING.............................. 1............M25000270
DECAL : NOTE........................................................ 1............M25000280
DECAL : LIFTING CAP ........................................... 1............M35000220
DECAL : OPERATING PROCEDURES .................. 1............M35000300A
DECAL : OIL DRAIN PLUG..................................... 1............M90000000
DECAL : WATER ..................................................... 1............M90010000
DECAL : - ................................................................ 1............M90030000
DECAL : + ............................................................... 1............M90030010
DECAL : DIESEL FUEL .......................................... 1............M90050000
DECAL : WARNING ................................................ 2............M90300000
DECAL : WATER - OIL CHECK............................... 1............M90300010
DECAL : WARNING ................................................ 1............M90310000
DECAL : WARNING ................................................ 1............M90320000
DECAL : DANGER .................................................. 1............M90320010
DECAL : FUEL DRAIN PLUG ................................. 1............M91000000
DECAL : DOCUMENT BOX LOCATED................... 1............M91000010
DECAL : CAUTION ................................................. 1............M91010000
DECAL : ENVIRONMENTAL WARNING................. 1............M91010030
DECAL : CAUTION ................................................. 1............M91010040
2
3
3
4
5
6
7
8
M1550002203
M2550002603
M2550002613
M2550002703
M2550002804
M3550002204
M3550003003
M9500000004
M9500100004
M9500300004
M9500300104
M9500500004
M9503000004
M9503000103
M9503100004
M9503200004
M9503200104
M9510000004
M9510000104
M9510100004
M9510100304
M9510100403
M9510200304
M9512200004
M9520000004
M9520000104
M9520000204
M9520000504
M9520000804
M9520000904
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520100603
M9520200003
M3560102004
M2560101803
M3560102204
M2560100703
M2560100803
M3560102504
0600500092
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
DECAL : MQ POWER
2
DECAL : MQ............................................................ 1............M91220000
DECAL : GROUND.................................................. 1............M92000000
DECAL : AMMETER CHANGE - OVER SW............ 1............M92000010
DECAL : VOLTMETER CHANGE - OVER SW........ 1............M92000020
DECAL : START CONTACT .................................... 1............M92000050
DECAL : AC............................................................. 1............M92000080
DECAL : DIAGNOSTIC SWITCH............................ 1............M92000090
DECAL : WARNING ................................................ 2............M92010000
DECAL : CAUTION ................................................. 1............M92010060
DECAL : SAFETY INSTRUCTIONS........................ 1............M92010030
DECAL : DANGER .................................................. 1............M92010040
DECAL : WARNING ................................................ 1............M92010050
DECAL : CAUTION ................................................. 2............M92010060
DECAL : CONNECTION OF OUTPUT CABLE....... 1............M92020000
STRIPE
2
2
2
1
1
2
1
4
STRIPE : WHISPERWATT
STRIPE
STRIPE : 85
STRIPE : 85
STRIPE
PLATE : MQ POWER
MACHINE SCREW
DECAL : WARNING S/N 8400921 AND ABOVE..... 1............M90420000
44A 0021106016
45 M9504200004
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 99
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TERMS AND CONDITIONS OF SALE — PARTS
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
6. The following items are not returnable:
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
LIMITATIONS OF SELLER’S LIABILITY
MINIMUM ORDER
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
RETURNED GOODS POLICY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
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
based on the list price that was effective
twelve months prior to the RMA date.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
e. The list must include the name
and phone number of the person
requesting the RMA.
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
3. AcopyoftheReturnMaterialAuthorization
must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
PAGE 100 — DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11)
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NOTES
DCA85USJ2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/22/11) — PAGE 101
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OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, MULTIQUIP INC.
Multiquip Inc, the MQ logo 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 their 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, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. 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.
Your Local Dealer is:
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