MULTIQUIP Power Ultra-Silent DCA-85USJ Operation And Parts Manual Download

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

PARTS LIST NO. M2870400004

Revision #0 (09/17/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

ULTRA-SILENT

SERIES

MODEL DCA-85USJ

GENERATOR

Summary of Contents for Power Ultra-Silent DCA-85USJ

Page 1: ...PARTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL PARTS LIST NO M2870400004 Revision 0 09 17 04 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES ULTRA SILENTTM SERIES MODEL DCA 85USJ GENERATOR...

Page 2: ...PAGE 2 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04...

Page 3: ...tions are based on the DCA 85USJ Ultra Silent Generator Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time wit...

Page 4: ...J UL UL UL UL ULTRA SILENT GENERA TRA SILENT GENERA TRA SILENT GENERA TRA SILENT GENERA TRA SILENT GENERATOR TOR TOR TOR TOR California Proposition 65Warning 2 Here s HowTo Get Help 3 Table Of Content...

Page 5: ...parts order system or by fax qualify for the following extra discounts Ordered Standard Stock orders via orders 750 list and above Fax 3 10 Web 5 10 Special freight allowances when you order 10 or mo...

Page 6: ...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 5 7 2 F T 5 4 0 4 E R E E D N H O J e p y T d e g r a h c o b r u t n o i t c e j n i t c e r i d d e l o o c r e t a w e l c y c 4 s r e...

Page 7: ...DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 PAGE 7 1 DCA 85USJ DIMENSIONS TOP SIDE AND FRONT Figure 1 Dimensions...

Page 8: ...ERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions Gasoline engine exhaust gas...

Page 9: ...nding environment Thisgenerator otherproperty or the surrounding environment could be damaged if you do not follow instructions NOTE NEVER tamper with the factory settings of the engine governor or se...

Page 10: ...injury or even DEATH This equipment is to be operated by trained and qualified personnel only This equipment is for industrial use only DANGER READTHIS MANUAL ALWAYS check the machine for loosened th...

Page 11: ...ipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC providesguidelinesforpropergroundingandspecifies that the cable ground shall be connecte...

Page 12: ...out of the radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the coolant drain plug while the engine is hot will result in hot coolant g...

Page 13: ...depending on type of terrain Place support blocks underneath the trailer s bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank Towi...

Page 14: ...Figures 2 3 These decals are provided for operator safety and maintenance information The illustration below and on the preceding page show the decals as they appear on the machine Should any of thes...

Page 15: ...DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 PAGE 15 1 DCA 85USJ GENERATOR DECALS Figure 3 Generator Decals Cont inued...

Page 16: ...PAGE 16 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 Figure 4 Typical Generator Grounding Application DCA 85USJ INSTALLATION...

Page 17: ...m2 or larger b Aluminum 8 AWG 8 4 mm2 or larger 2 When grounding the generator Figure 4 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect...

Page 18: ...and D Duringsteadystateloads thepowerfromthevoltageregulator 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...

Page 19: ...N O I T P I R C S E D 1 y l b m e s s A r e l f f u M 2 y l b m e s s A e n i g n E 3 y l b m e s s A e r u s o l c n E 4 y l b m e s s A r o t a r e n e G 5 y l b m e s s A l a n i m r e T t u p t u...

Page 20: ...PAGE 20 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 NOTE PAGE...

Page 21: ...tage present at the U V and W OutputTerminal Lugs 6 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals o...

Page 22: ...PAGE 22 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 Figure 7 Engine Operating Panel DCA 85USJ ENGINE OPERATING PANEL...

Page 23: ...uate the fault and all major faults will shutdown the generator 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...

Page 24: ...20V GFCI receptacles 20 amp Two 2 GFCI Circuit Breakers 20 amps Five 5 Output Terminal Lugs U V W O Ground OutputTerminal Panel TheOutputTerminalPanel Figure8 shownbelowislocated ontheright handside l...

Page 25: ...urrent on all three receptacles is dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Tu...

Page 26: ...circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated in the contro...

Page 27: ...tention to the required starting current capacity NOTE WATTS VOLTAGE x AMPERAGE Three Phase Load When calculating the power requirements for 3 phase power use the following equation NOTE An inadequate...

Page 28: ...ed above the output terminal panel s Hard Wire Hook up Panel It has been provided for ease of voltage selection Voltage Selector Switch Locking Button The voltage selector switch has a locking button...

Page 29: ...139 position Figure 21 AC Ammeter Amp reading on U lug Figure 20 AC Ammeter Change Over Switch The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in u...

Page 30: ...inal Lugs 240 139VThree Phase Connections 2 Connect the load wires to the OutputTerminal Lugs as shown in Figure 22 3 Turn the voltage regulator knob Figure 23 clockwise to increase voltage output tur...

Page 31: ...regulator knob Figure 24 clockwise to increase voltage output turn counterclockwise to decrease voltage output 1 240V 120V OutputTerminal LugVoltages 1 Place the voltage selector switch in the 1 240...

Page 32: ...ll the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 31...

Page 33: ...Figure 35 Figure 35 Full FuelTank Figure 36 Fuel Expansion 3 Open cabinet doors on the right side of the generator fromgeneratorcontrolpanelposition Removefuelcap and fill tank Figure 34 Figure 34 Fue...

Page 34: ...d off and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the John Deere Engine Owner s Manual Fan BeltTension A slack f...

Page 35: ...clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close...

Page 36: ...he Output Terminal Lugs as shown in Figure 13 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 3 The output terminal lugs a...

Page 37: ...ired voltage Figure 46 Voltmeter Figure 45 Frequency Meter Hz 9 The generator s frequency meter Figure 45 should be displaying the 60 cycle output frequency in HERTZ 8 Place the MPEC Control Switch in...

Page 38: ...mperature Gauge Figure 52 Main Aux and GFCI Circuit Breakers ON 15 Place the main GFCI and aux circuit breakers in the ON position Figure 52 16 Observe the generator s ammeter Figure 53 and verify it...

Page 39: ...nerated automatically by a transfer switch NOTE Starting Auto Mode Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch...

Page 40: ...5 Verify that the all status LED on the MPEC display are OFF not lit 6 Remove all loads from the generator DCA 85USJ GENERATOR SHUT DOWN PROCEDURE Emergency Shutdown Procedure 1 To shut down the engi...

Page 41: ...l b e h t f o e p o l s e h t t a h t e r u s n e d e c a l p e r e b o t s d e e n e s o h y b w o l b f I 4 l i o r o d n a e r u t s i o m t c e l l o c d l u o c t a h t s p i d r o s g a s o n DC...

Page 42: ...Replace with coolant as recommended by the engine manufaturer Close radiator cap tightly Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After runnin...

Page 43: ...ll ONLY function when commercial power has been supplied to them Figure 56 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 5 When using the gene...

Page 44: ...equirement 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 45: ...ingrequirestheinstallationofanactuator 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...

Page 46: ...ressure to particular load per tire manufacturer EdgeWear Under Inflation Adjust pressure to particular load per tire manufacturer SideWear Loss of camber or overloading Make sure load does not exceed...

Page 47: ...uts all the way down Tighten each lug nut in 3 separate passes as defined by Table 17 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically NEVER use an pneuma...

Page 48: ...PAGE 48 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ TRAILERWIRING DIAGRAM Figure 60 Trailer Towing Vehicle Wiring Diagram...

Page 49: ...DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 PAGE 49 1 DCA 85USJ GENERATORWIRING DIAGRAM Figure 61 GeneratorWiring Diagram...

Page 50: ...PAGE 50 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENGINEWIRINGDIAGRAM Figure 62 Engine Wiring Diagram...

Page 51: ...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 d l e i F r e t i c x E e v i t c e f e D 1 N C n o K J s s o r c a s m h o 3 7 1 r o f 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...

Page 52: ...g i H n o s i t h g i l t c e r r o c n i n o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r...

Page 53: ...DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 PAGE 53 1 NOTE PAGE...

Page 54: ...lar 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...

Page 55: ...RA SILENT GENRATOR W JOHN DEERE 4045TF275 DIESEL ENGINE 1TO 3 UNITS Qty P N Description 5 0602041292 FILTER OIL 5 0602042594 FILTER FUEL PRIMARY 5 0602042595 FILTER FUEL FINAL 3 0602046377 ELEMENT AIR...

Page 56: ...PAGE 56 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ GENERATOR ASSY GENERATOR ASSY...

Page 57: ...311DDUC3 2 M2163400003 COUPLING RING 1 3 0343204170 HEX HEAD BOLT 8 4 0043604000 SPRINGWASHER 8 5 B6130000303 STATOR ASSY 1 B6134000304 6 0845041804 GROMMET 2 7 8101315202 END BRACKET 1 8 8101350013 F...

Page 58: ...PAGE 58 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ CONTROL BOX ASSY CONTROL BOX ASSY...

Page 59: ...1 15 0016906016 HEX HEAD BOLT 4 16 M3270100104 SELECTOR SWITCH 1 XUSS01574 INCLUDES ITEMS W 16A TBD KNOB SELECTOR SWITCH 1 17 M3276600004 SPACER 8 18 M3213600503 SWITCH BRACKET 1 19 0330000330 EDGING...

Page 60: ...PAGE 60 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ CONTROL BOX ASSY CONTROL BOX ASSY...

Page 61: ...LIGHT 1 90 0001 44 M1223100004 STOPPER 1 45 M3223100004 STOPPER 1 46 0027105010 MACHINE SCREW 4 47 0027105010 MACHINE SCREW 4 48 M9220100004 SET SCREW 2 49 0080200007 SNAP RING 2 50 0602202592 STARTE...

Page 62: ...PAGE 62 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENGINE RADIATOR ASSY ENGINE RADIATOR ASSY...

Page 63: ...BBER SUSPENSION 2 10 0030012000 HEX NUT 2 11 0040012000 SPRINGWASHER 2 12 C0923200124 RADIATOR 1 232000 3240 12 1 0602011062 CAP 1 102600 0380 13 M9200100904 PLUG 1 14 0150000016 O RING 1 15 001691002...

Page 64: ...PAGE 64 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENGINE RADIATOR ASSY ENGINE RADIATOR ASSY...

Page 65: ...00303 BRACKET RESERVE TANK 1 42 0016908020 HEX HEAD BOLT 3 43 0199102200 HOSE 1 44 0193600700 HOSE 1 45 0193601000 HOSE 1 46 0605515106 HOSE BAND 3 47 M2326000104 BLOWBY HOSE 1 48 0605515149 HOSE BAND...

Page 66: ...PAGE 66 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY...

Page 67: ...2 11 0027103010 MACHINE SCREW 8 11A 0041203000 PLAINWASHER 4 12 0030003000 HEX NUT 8 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPP...

Page 68: ...PAGE 68 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ BATTERY ASSY BATTERY ASSY...

Page 69: ...RT NAME QTY REMARKS 1 0602220187 BATTERY 1 627MFD 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M2346900204 BATTERY CABLE 1 6 M2346900304 BATTERY CABLE 1...

Page 70: ...PAGE 70 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ MUFFLER ASSY MUFFLER ASSY...

Page 71: ...NO PART NO PART NAME QTY REMARKS 1 M2330100703 MUFFLER 1 2 0017112030 HEX HEAD BOLT 4 3 M2333000703 EXHAUST PIPE 1 4 M2333200204 GASKET 1 5 0017110040 HEX HEAD BOLT 4 6 M3333200204 GASKET 1 7 00171100...

Page 72: ...PAGE 72 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ FUELTANK ASSY FUEL TANK ASSY...

Page 73: ...3 FUEL SENDER UNIT 1 1 3 0605516090 GASKET 1 2 M2363200404 TANK BAND 6 3 M9310500104 SUPPORTER SHEET 6 4 0016908020 HEX HEAD BOLT 6 5 0016908040 HEX HEAD BOLT 3 5A 0207308000 HEX NUT 3 6 0191302040 VE...

Page 74: ...PAGE 74 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY...

Page 75: ...AME 1 S N 8400001TO 8400030 6 M2423001002 FRONT FRAME 1 S N 8400031 6A M2493102813 ACOUSTIC SHEET 1 S N 8400001TO 8400030 6A M2493104103 ACOUSTIC SHEET 1 S N 8400031 7 0601851739 GROMMET 1 S N 8400001...

Page 76: ...L NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO G...

Page 77: ...04 ACOUSTIC SHEET 1 30 M2463200102 ROOF PANEL 1 30A M2493502203 ACOUSTIC SHEET 1 31 M3463200704 BACK PLATE 2 32 0016906016 HEX HEAD BOLT 12 33 M2463200203 DUCT 1 33A M2493502104 ACOUSTIC SHEET 1 34 00...

Page 78: ...PAGE 78 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY...

Page 79: ...304 WINDOW PLATE 1 9 0207306000 HEX NUT 8 9A 0041206000 PLAINWASHER 8 10 M9113000002 DOOR HANDLE ASSY 1 11 0021806016 MACHINE SCREW 4 11A 0030006000 HEX NUT 4 12 M9110100204 HINGE 2 13 M9116100004 WAS...

Page 80: ...PAGE 80 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY...

Page 81: ...NDLE ASSY 4 22A C9312500004 SEAL RUBBER 4 23 0021806016 MACHINE SCREW 16 23A 0030006000 HEX NUT 16 24 M9110100804 HINGE 6 25 M9110100904 HINGE 5 26 M9116100004 WASHER 11 27 0016908020 HEX HEAD BOLT 26...

Page 82: ...PAGE 82 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ RUBBER SEALS ASSY RUBBER SEALS ASSY...

Page 83: ...QTY REMARKS 1 0229200870 RUBBER SEAL 1 2 0229201130 RUBBER SEAL 1 3 0229201240 RUBBER SEAL 3 4 0228900660 RUBBER SEAL 2 5 0229201070 RUBBER SEAL 1 6 0229200125 RUBBER SEAL 4 7 0228901165 RUBBER SEAL...

Page 84: ...PAGE 84 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ NAME PLATE ASSY NAME PLATE ASSY...

Page 85: ...1 M90050000 12 M9503000004 DECAL WARNING MOVING PARTS 2 M90300000 13 M9503000103 DECAL WATER OIL CHECK 1 M90300010 14 M9503100004 DECAL WARNING HOT COOLANT 1 M90310000 S N 8400001 8400030 14 M9503100...

Page 86: ...PAGE 86 DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 DCA 85USJ NAME PLATE ASSY NAME PLATE ASSY...

Page 87: ...L WARNING 1 M92010050 28 M9520100603 DECAL CAUTION 2 M92010060 29 M9520200003 DECAL CONNECTION OF OUTPUT CABLE 1 M92020000 30 0021106016 MACHINE SCREW 4 S N 8400031 31 M9512200004 DECAL MQ 1 M91220000...

Page 88: ...ts g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pending in...

Page 89: ...DCA 85USJ OPERATION AND PARTS MANUAL REV 0 09 17 04 PAGE 89 1 NOTE PAGE...

Page 90: ...HERE S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBERON HANDWHENCALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower multiquip co...

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