MULTIQUIP MQ POWER DCA-85SSJU WHISPERWATT Parts And Operation Manual Download

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PAGE 68 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

ENGINE & RADIATOR ASSY.

DCA-85SSJU — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

Summary of Contents for MQ POWER DCA-85SSJU WHISPERWATT

Page 1: ...TMENT 18910 WILMINGTON AVE 800 427 1244 CARSON CALIFORNIA 90746 FAX 800 672 7877 310 537 3700 SERVICE DEPARTMENT 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 E mail mq multiquip com www...

Page 2: ...PAGE 2 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01...

Page 3: ...EL AND SERIAL NUMBER ON HANDWHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 WARRANTY DEPART...

Page 4: ...d Application 46 Generator Start up Procedure 47 49 Generator Start up Procedure Auto 50 Generator Shut Down Procedure 51 Maintenance 52 53 GeneratorWiring Diagram 54 EngineWiring Diagram 55 EngineTro...

Page 5: ...f line items ordered Additional Discount 1 9 items 3 10 items 5 Now Direct TOLL FREE access to our Parts Department Toll free nationwide 800 421 1244 Toll free FAX 800 6 PARTS 7 800 672 7877 Dealer ac...

Page 6: ...should not be operated by persons under 18 years of age NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by...

Page 7: ...ienttimefortheengineandgenerator to cool before performing maintenance Radiator 1 Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to gush o...

Page 8: ...e generator always use the balanced center point suspension hook and lift straight upwards NEVER allow any person or animal to stand underneath the machine while lifting When loading the generator on...

Page 9: ...dfirstaidkit Knowthelocationofthenearesttelephone Also know the phone numbers of the nearest ambulance doctor and fire department Maintenance Safety NEVER lubricate components or attempt service on a...

Page 10: ...Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain DCA 85SSJU TOWING RULES FOR SAFE OPERATION ALWAYS attach trailer s safety chain to bumper o...

Page 11: ...requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175...

Page 12: ...7 0 6 5 4 A C D O N E G R U S S B L 0 0 0 7 6 8 1 7 7 B L 0 0 0 2 D A P T A L F X 0 7 R L R T 0 7 0 6 5 4 A C D T P O E G R U S S B L 0 0 0 7 8 3 1 6 6 B L 0 0 0 2 D A P T A L F F X 0 7 R L R T 0 7 0...

Page 13: ...B U R E L O P 4 T A L F X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 R E B B U R E L O P 4 T A L F F X 0 7 R L R T S S A L C...

Page 14: ...d by road testing Brake lockup grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under adjusted brakes Before any brake synchronizations...

Page 15: ...lacement These brakes can be adjusted in the same manner as electric brakes Brake lines should be periodically checked for cracks kinks or blockage Figure 3 below displays the major hydraulic air surg...

Page 16: ...actor 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 w...

Page 17: ...0 4 5 3 5 6 0 5 3 1 5 2 0 2 0 4 5 3 5 6 0 5 4 1 5 2 0 2 0 6 0 5 0 2 1 0 9 5 1 5 2 0 2 0 6 0 5 0 2 1 0 9 6 1 5 2 0 2 0 6 0 5 0 2 1 0 9 Lug NutTorque Requirements It is extremely important to apply and...

Page 18: ...PAGE 18 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 NOTE LIGHTS ARE ORIENTED FROM THE DRIVER S SEAT DCA 85SSJU TRAILER WIRING DIAGRAM...

Page 19: ...r B k a e W e d i S e n O s g n i n i l r o s t e n g a m n o l i o r o e s a e r G e c a l p e r r o n a e l C d e d o r r o c s n o i t c e n n o C e s u a c t c e r r o c d n a n a e l C n o i s o...

Page 20: ...y l l a u q e s e r i t l l a e t a l f n I e l x a e m a s e h t n o d e h c t a m n u s e r i T s e r i t h c t a M s e k a r B g n i k c o L n e k o r b r o t n e b e s o o l s t n e n o p m o c e...

Page 21: ...ator is equipped with a number of safety decals These decals are provided for operator safety and maintenance information The illustration below and on the preceding pages show the decals as they appe...

Page 22: ...PAGE 22 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 DCA 85SSJU GENERATOR DECALS...

Page 23: ...e w o P C A x u A z H 0 6 e s a h P e l g n i S e g a t l o V V 0 2 1 t u p t u O 2 x W K 4 2 W K 8 4 s n o i t a c i f i c e p S e n i g n E l e d o M 0 5 2 F T 5 4 0 4 E R E E D N H O J e p y T d e...

Page 24: ...ngine specifications In keeping with Multiquip s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice The basic controls and indicato...

Page 25: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 25 DCA 85SSJU MAJOR COMPONENTS Figure 6 Major Components...

Page 26: ...PAGE 26 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 DCA 85SSJU DIMENSIONS Figure 7 Dimensions...

Page 27: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 27 Figure 3b Dimensions NOTE PAGE...

Page 28: ...PAGE 28 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 DCA 85SSJU CONTROL PANEL Figure 8 Control Panel...

Page 29: ...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 4 Voltmeter Change Over S...

Page 30: ...PAGE 30 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 DCA 85SSJU ENGINE OPERATING PANEL Figure 9 Engine Operating Panel...

Page 31: ...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 eng...

Page 32: ...11 120Volt Recetacle Two GFCI Duplex Nema 5 20R 120V 20 Amp recepacle is provided on the output terminal This receptacle can be used anytime the generator is in operation The receptacle is controlled...

Page 33: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 33 Legs O and Ground are considered Bonded Grounds NOTE DCA 85SSJU OUTPUTTERMINAL PANEL OVERVIEW FIGURE 14 Output Terminal Panel...

Page 34: ...n the red button located on the Voltage Selector Switch and use a pad lock to hold it into this position See figure 17 page 37 Over Current Relay An over current relay is connected to the circuit brea...

Page 35: ...d the AC ammeter Change over Switch to the U or W position to read the output on the selected leg A 0 40 60 75 20 FIGURE 15 Voltage Selector Switch 240 120V Single Phase Position FIGURE 16 AC Voltmete...

Page 36: ...e Hookup The output terminal panel when suppling three phase 240 volts will provide one circuit available at 198 amps with any twowiresplustheground SeeFigure23below Thevoltage selector switch must be...

Page 37: ...up the hard wires to the lugs as shown in figure 27 below 480V will be the voltage with the Voltage Regulator Knob turned toward maximum 440 volt will be reached when the Voltage Regulator Knob is tu...

Page 38: ...g up the hard wires to the lugs as shown in figure 32 below 240V will be the voltage with the Voltage Regulator Knob turned toward maximum 220 volt will be reached when the Voltage Regulator Knob is t...

Page 39: ...shown in figure 36 below use the Voltage Regulator Knob to fine tune to 240V See Figure 35 Single Phase 120 Volt The following connection with the voltage selector switch locked into the single phase...

Page 40: ...to rain or sunshine 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 d...

Page 41: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 41 Figure 38 Typical Generator Grounding Application DCA 85SSJU INSTALLATION...

Page 42: ...to Operation The DCA 600SSK generator has been thoroughly inspectedandacceptedpriortoshipmentfromthefactory However be sure to check for damaged parts or components or loose nuts and bolts which coul...

Page 43: ...il be sure to check if the oil is clean and viscous If the oil is not clean drain the oil by removingtheoildrainplug andrefillwiththespecifiedamount of oil as outlined in the John Deere Engine Owner s...

Page 44: ...oaded 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 battery disconnected Air Cl...

Page 45: ...terminals This will ensure a good connection and will help prevent corrosion around the battery terminals CAUTION CAUTION CAUTION CAUTION CAUTION Inadequatebatteryconnectionsmaycause poor starting of...

Page 46: ...power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output kW multiplied by 0 8 can be used d...

Page 47: ...l immediately Before Starting Generator and Control Panel CAUTION 1 Be sure to disconnect the electrical load and switch the main load and G F C I circuit breakers Figure 43 to the OFF position prior...

Page 48: ...Speed Switch high Figure 48 Voltage Selection Switch 4 Close all engine enclosure doors Figure 46 Figure 46 Engine Enclosure Doors 5 WhenstartingthegeneratorinCOLDweatherconditions press and hold the...

Page 49: ...amount of current that the load is drawing from the generator s alternator 13 The engine oil pressure gauge Figure 56 will indicate the oil pressure kg cm2 of the engine Under normal operating conditi...

Page 50: ...N Starting the generator in the AUTO mode is similar to starting the generator in the MANUAL mode with a few exceptions When running the generator in the AUTO mode remember the generator can start up...

Page 51: ...engine cool by running it for 3 5 minutes with no loadapplied 4 Turn the Auto Off Reset Manual switch from the engine controller to OFF Reset position Figure 64 Figure 63 Engine Speed Switch Figure 64...

Page 52: ...t Refer to the Engine Instruction Manual Air Cleaner Every50hours Removeaircleanerelementandcleanheavy duty paper element with kerosene or foam element with liquid detergent and hot water Wrap foam el...

Page 53: ...p e R 1 X r e t l i F r i A n a e l C X k n a T l e u F f o m o t t o B n i a r D X e d i s t u O d n a e d i s n I t i n U n a e l C X r e t l i F l e u F e g n a h C 2 X n o i t c e t o r P t n a l...

Page 54: ...PAGE 54 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 DCA 85SSJU GENERATORWIRING DIAGRAM...

Page 55: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 55 DCA 85SSJU ENGINEWIRING DIAGRAM...

Page 56: ...e u f d e i f i c e p s e h t e s U r e b m u n e n a t e c w o l h t i w l e u F l e u f d e i f i c e p s e h t e s U n o i t c e j n i e s o o l o t e u d k a e l l e u F t u n g n i n i a t e r e...

Page 57: ...f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m...

Page 58: ...e f e d R V A s I y r a s s e c e n f i e c a l p e R r e i f i t c e R g n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g...

Page 59: ...w o l f r i A l l i r g r o t a i d a r r i a p e r n a e l C n e p o s r o o D s r o o d e s o l C g n i k a e l t s u a h x E t r a p y t l u a f r o s t e k s a g r i a p e r e c a l p e R d e d a...

Page 60: ...part is used Model Number Where indicated this shows that the corresponding part is utilized only with this specific model number or model number variant Items Found In the Items Number Column All par...

Page 61: ...ITCH STARTER 5 615 KEY SET STARTER SWITCH 2 2 0602122281 OIL SWITCH 1 6152611520 RADIATOR HOSE UPPER 1 6152611531 RADIATOR HOSE LOWER 1 0802010900 FUEL CAP 1 061820625 AUTOMATICVOLTAGE REGULATOR 1 060...

Page 62: ...PAGE 62 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 GENERATOR ASSY DCA 85SSJU GENERATOR ASSY GENERATOR ASSY...

Page 63: ...EXCITER 1 21 0012110070 HEX HEAD BOLT 4 22 0042610000 LOCKWASHER 4 23 031110160 PLAINWASHER 4 REPLACES 0041210000 24 0010110035 HEX HEAD BOLT 6 25 0040010000 LOCKWASHER 6 26 031110160 PLAINWASHER 6 R...

Page 64: ...PAGE 64 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 CONTROL BOX ASSY DCA 85SSJU CONTROL BOX ASSY...

Page 65: ...ACHINE SCREW 2 REPLACES 0027104015 0030004000 HEX NUT 2 REPLACES 0207004000 13 LY2US12VD RELAY 1 REPLACES 0601823768 PTF08AE BASE 1 REPLACES 0601823109 PYCA1 CLIP 2 REPLACES 0601824400 14 0027104020 M...

Page 66: ...PAGE 66 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 CONTROL BOX ASSY DCA 85SSJU CONTROL BOX ASSY CONTROL BOX ASSY...

Page 67: ...L 2VS 31 0601840073 RHEOSTAT VOLTAGE REGULATOR 1 RA20A2SE102BJ 2W 1K OHM 32 0601840121 KNOB 1 33 M1223100004 STOPPER 1 34 0027105010 MACHINE SCREW 2 35 0027105010 MACHINE SCREW 4 36 M9220100004 SET SC...

Page 68: ...PAGE 68 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 ENGINE RADIATOR ASSY DCA 85SSJU ENGINE AND RADIATOR ASSY ENGINE RADIATOR ASSY...

Page 69: ...ADIATOR HOSE 1 15 M2310500603 RADIATOR HOSE 1 16 0605515147 HOSE BAND 3 17 0605515201 HOSE BAND 1 18 0602046582 AIR CLEANER 1 FPG082527 0602046365 ELEMENT AIR CLEANER 1 P828889 19 0602040651 INDICATOR...

Page 70: ...PAGE 70 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 ENGINE RADIATOR ASSY DCA 85SSJU ENGINE AND RADIATOR ASSY ENGINE RADIATOR ASSY...

Page 71: ...006000 45 011808015 MACHINE SCREW 2 REPLACES 0027106015 46 M2483400014 ALTENATOR COVER 1 47 011206020 HEX HEAD BOLT 2 REPLACES 0016906020 48 0602122281 OIL SWITCH 1 1718939011 49 M9200100704 ADAPTER 1...

Page 72: ...PAGE 72 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 ENGINE OPERATING PANEL ASSY DCA 85SSJU ENGINE OPERATING PANEL ASSY...

Page 73: ...100182 5 0602123261 UNIT WATERTEMPERATURE 1 0202500 6 0602121080 CHARGING AMMETER 1 100158 7 0602125090 FUEL GAUGE 1 100176 8 0601831585 PREHEAT BUTTON 1 44047 0601831586 CAP 1 44053 9 0601831395 ENG...

Page 74: ...PAGE 74 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 OUTPUT TERMINAL ASSY DCA 85SSJU OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY...

Page 75: ...REPLACES 0030003000 13 011106015 HEX HEAD BOLT 2 REPLACES 0016906015 14 011106015 HEX HEAD BOLT 4 REPLACES 0016906015 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1...

Page 76: ...PAGE 76 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 BATTERY ASSY DCA 85SSJU BATTERY ASSY BATTERY ASSY...

Page 77: ...3000304 BATTERY BAND 1 4 06022209020 BATTERY BOLT SET 2 5 0040006000 LOCKWASHER 2 6 M1346400204 BATTERY CABLE 1 7 M2346400104 BATTERY CABLE 1 8 011008020 HEX HEAD BOLT 1 REPLACES 0016908020 0040508000...

Page 78: ...PAGE 78 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 MUFFLER ASSY DCA 85SSJU MUFFLER ASSY MUFFLER ASSY...

Page 79: ...2 012210025 HEX HEAD BOLT 4 REPLACES 0016910025 3 M2335000003 EXHAUST PIPE 1 4 0602325066 CLAMP 1 MOO1432 5 M2333200004 GASKET 1 REPLACES M2333200014 6 0016908040 HEX HEAD BOLT 4 7 M2330400314 COVER 1...

Page 80: ...PAGE 80 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 FUEL TANK ASSY DCA 85SSJU FUELTANK ASSY FUEL TANK ASSY...

Page 81: ...00 HEX NUT 2 7 0222100178 RUBBER SHEET 4 8 M9200000003 DRAIN JOINT 1 9 M9200200004 DRAIN BOLT 1 10 0150000018 O RING 1 11 011206020 HEX HEAD BOLT 2 REPLACES 0016906020 12 M1363400104 DRAIN HOSE 1 13 0...

Page 82: ...DCA 85SSJU ENCLOSURE ASSY ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GREEN 5 BL...

Page 83: ...LAINWASHER 8 REPLACES 0041214000 13 012212030 HEX HEAD BOLT 10 REPLACES 0017112030 14 M2445000103 REAR FRAME 1 M2493300904 ACOUSTIC SHEET 1 15 011008020 HEX HEAD BOLT 4 REPLACES 0016908020 16 M2445300...

Page 84: ...DCA 85SSJU ENCLOSURE ASSY ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GREEN 5 BL...

Page 85: ...453000603 SIDE DOOR 1 M2493401104 ACOUSTIC SHEET 1 40 M2455000103 SIDE DOOR 1 M2495400304 ACOUSTIC SHEET 1 41 M2455000203 SIDE DOOR 1 M2495400004 ACOUSTIC SHEET 1 42 M2453300503 DUCT 1 M2493401004 ACO...

Page 86: ...PAGE 86 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 RUBBER SEALS ASSY DCA 85SSJU RUBBER SEALS ASSY RUBBER SEALS ASSY...

Page 87: ...4 SEAL RUBBER 1 6 0228800665 SEAL RUBBER 1 7 0228900425 SEAL RUBBER 1 8 0228900860 SEAL RUBBER 1 9 0228900630 SEAL RUBBER 1 10 0229200900 SEAL RUBBER 2 11 0229200840 SEAL RUBBER 1 12 0228800770 SEAL R...

Page 88: ...PAGE 88 DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 NAME PLATE ASSY DCA 85SSJU NAMEPLATE AND DECAL ASSY...

Page 89: ...ING MOVING PARTS 2 M9030 0000 17 M9503000103 DECAL WATER OIL CHECK 1 M9030 0010 18 M9503100004 DECAL WARNING HOT COOLANT 1 M9031 0000 19 M9503200004 DECAL WARNING ENGINE EXHAUST 1 M9032 0000 20 M95101...

Page 90: ...be liable here under for damagesinexcessofthepurchasepriceofthe 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 othe...

Page 91: ...DCA 85SSJU PARTS AND OPERATION MANUAL REV 2 12 21 01 PAGE 91 NOTE PAGE...

Page 92: ...ANTY DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 Manufactured for Multiquip Inc by DENYO MANUFACTURING CO USA MULTIQUIP INC POST OFFICE...

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