Multiquip Portable Generator DCA85usJ2 User Manual

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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