MULTIQUIP Whisperwatt DCA150SSJU4F Operation And Parts Manual Download

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dca150ssju4f 60 hz generator• operation manual — rev. #0 (11/0614) — page 89

NaMepLate aND DeCaLs assy.

no.

part no.

part name

QtY.

remarks

1-1

M3551000103

DECAL: OPERATING PROCEDURES .............1................M35100010

1-2

M3551000303

DECAL: DPF REGENERATION PROC. ............1................M35100030

1-3

M9520100304

DECAL: SAFETY INSTRUCTIONS ..................1................M92010030

1-4

M9520100603

DECAL: CAUTION ............................................2................M92010060

control panel and Box group

2-1

M3551000502

DECAL: CONTROL PANEL ..............................1................M35100050

2-2

M9520000104

PLATE: AMMETER CHANGE-OVER SW. ........1................M92000010

2-3

M9520000204

PLATE: VOLTMETER CHANGE-OVER SW. .....1................M92000020

2-4

M9520100004

DECAL: WARNING: ELECTRICAL SHK. HAZ. .2................M92010000

2-5

M9520100704

DECAL: WARNING: ARC FLASH .....................1................M92010070

2-6

M9520200404

DECAL: OVER CURRENT RELAY ...................1................M92020040

2-7

M9522000504

DECAL: CIRCUIT BREAKER ...........................1................M92200050

2-8

M9520100204

DECAL: CAUTION ............................................1................M92010020A

engine and radiator group

3-1

M9500000004

DECAL: OIL DRAIN PLUG ...............................1................M90000000

3-2

M9500100004

DECAL: WATER ................................................1................M90010000

3-3

M9503000004

DECAL: WARNING: ROTATING PART ..............2................M90300000

3-4

M9503000103

DECAL: WATER-OIL CHECK ...........................1................M90300010

3-5

M9503100004

DECAL: WARNING: HOT COOLANT ...............1................M90310000

3-6

M9510100004

DECAL: CAUTION: HOT PARTS ......................1................M91010000

output terminal group

4-1

M1550002203

DECAL: RECEPTACLE & CIRC. BREAKER .....1................M15000220

4-2

M9520000004

DECAL: GROUND ............................................2................M92000000

4-3

M9520000504

DECAL: START CONTACT ...............................1................M92000050

4-4

M9520200003

DECAL: CONNECTION OF OUTPUT CABLE .1................M92020000

4-5

M9520100404

DECAL: DANGER: HIGH VOLTAGE .................1................M92010040

4-6

M9520100503

DECAL: WARNING ...........................................1................M92010050

4-7

M9511100104

DECAL: NOTICE ...............................................1................M91110010

4-8

M3550000804

DECAL: NOTICE ...............................................1................M35000080A

BatterY group

5-1

M9500300004

DECAL: - ...........................................................1................M90030000

5-2

M9500300104

DECAL: + ..........................................................1................M90030010

5-3

M9510100403

DECAL: CAUTION ............................................1................M91010040

5-4

M9501300004

DECAL: CAUTION ............................................1................M90130000

muffler group

6-1

M9503200004

DECAL: WARNING: ENGINE EXHAUST ..........1................M90320000

6-2

M9503200104

DECAL: DANGER: EXHAUST ..........................1................M90320010

6-3

920214100

DECAL: WARNING: START FIRES ..................1................M90420000

.............................................................................................REPLACES P/N M9504200004

Summary of Contents for Whisperwatt DCA150SSJU4F

Page 1: ...IMES To find the latest revision of this publication visit our website at www mqpower com Whisperwatt Series MODEL DCA150SSJU4F 60Hz GENERATOR JOHN DEERE 6068HFG08 DIESEL ENGINE PARTS LIST NO M3871300204 Revision 0 11 06 14 Operation and parts Manual ...

Page 2: ...page 2 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 proposition 65 warning Diesel engine exhaust and some of ...

Page 3: ... 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 Inc 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 safercar gov or...

Page 4: ...nual 32 33 Generator Start Up Procedure Auto Mode 34 Generator Shut Down Procedures 35 Maintenance 36 43 Trailer Maintenance 44 48 Trailer Wiring Diagram 49 Generator Wiring Diagram 50 Engine Wiring Diagram 51 Troubleshooting Generator 52 Troubleshooting Diagnostics 53 Explanation of Code in Remarks Column 54 Suggested Spare Parts 55 Component Drawings Generator Assembly 56 57 Control Panel Assemb...

Page 5: ...DCA150ssju4f 60 hz generator operation manual rev 0 11 0614 page 5 notes ...

Page 6: ...e 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 situati...

Page 7: ...recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result 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 inval...

Page 8: ...ction 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 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 no...

Page 9: ...ting condition alWaYs shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating 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...

Page 10: ... 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 Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE alWaYs make certain that proper power or extension cord ha...

Page 11: ...f this equipment is over remove battery and bring to appropriate facility for lead reclamation Use safety precautions when handling batteries that contain sulfuric acid When the life cycle of this equipment is over it is recommended that the trowel frame and all other metal parts be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transfor...

Page 12: ...W x 2 Dry Weight 6 615 lbs 3 000 kg Wet Weight 7 497 lbs 3 400 kg Table 2 Engine Specifications Model John Deere 6068HF08 Tier 4 Final Certified Type 4 cycle water cooled direct injection turbo charged charged air cooled EGR DOC DPF and SCR No of Cylinders 6 cylinders Bore x Stroke 4 17 in x 4 99 in 106 mm x 127 mm Displacement 4015 cu in 6 8 liter Rated Output 240 HP at 1800 rpm Starting Electric...

Page 13: ...A E B C D MAXIMUM LIFTING POINT 14 050 lbs 6 373 kg 150 Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 35 83 in 910 mm E 43 70 in 1 110 mm B 35 83 in 910 mm F 137 79 in 3 500 mm C 43 70 in 1 110 mm G 68 89 in 1 750 mm D 41 33 in 1 050 mm H 51 18 in 1 300 mm Figure 1 Dimensions ...

Page 14: ...tion and Parts manual rev 0 11 06 14 Installation GENERATOR GROUND LUG GROUND CABLE REFERENCE NEC 250 83 C GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND IF APPLICABLE 8 FT 2 4 M MINIMUM Figure 2 Typical Generator Grounding Application ...

Page 15: ...ator 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 CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exha...

Page 16: ...allel 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 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 ...

Page 17: ...10 60 Engine Started Shutdown Pre Alarm Series 800 Controller Alarm Acknowledge Screen Change Program Exit Option ECU 1 2 3 4 5 6 7 8 11 9 10 Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Muffler Assembly 2 Enclosure Assembly 3 Generator Assembly 4 Battery Assembly 5 Engine Assembly 6 Fuel Tank Assembly 7 Output Terminal Assembly 8 Circuit Breaker Assembly 9 Auto Start Stop Controller A...

Page 18: ...C Engine Shutdown Lamp When an engine failure has occured this lamp will blink Indicating the engine has been shutdown The diagnostic fault message will be displayed on the LCD screen D Pre Alarm Lamp When an engine failure has occured this lamp will blink Indicating a pre fault engine condition and the possibility of engine shutdown The diagnostic fault message will be displayed on the LCD screen...

Page 19: ...5 100 F WATER TEMP 100 140 180 220 260 VOLTS BATTERY 6 12 18 24 30 F FUEL E F RPMX10 SPEED 0 120 150 180 210 60 D A B C E 1 PSI OIL PRESS 0 25 50 75 100 F WATER TEMP 100 140 180 220 260 VOLTS BATTERY 6 12 18 24 30 F FUEL E F RPMX10 SPEED 0 120 150 180 210 60 Series 800 Controller ECU Engine Started Shutdown Pre Alarm Alarm Acknowledge Screen Change Program Exit Option OFF U V W U V W OFF V W U INC...

Page 20: ... Output Terminal Panel Figure 7 is provided with the following Three 3 240 139V output receptacles 50 amp Three 3 Circuit Breakers 50 amps Two 2 120V GFCI receptacles 20 amp Two 2 GFCI Circuit Breakers 20 amps Eight 8 Output Terminal Lugs U V W O Ground AUX POWER RECEPTACLES 240 139V 50 AMPS 120 VAC 20 AMP GFCI RECEPTACLES Y X W CS 6369 TWIST LOCK CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLE...

Page 21: ... Both receptacles should be tested at least once a month Figure 7 G F C I Receptacle Twist Lock DualVoltage 120 240VAC Receptacles There are three 240 139V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage change over board is configured for single phase 240 120 application Figure 8 240 139V Twist ...

Page 22: ...FCI RECEPTACLE LOAD CS 6369 TWIST LOCK RECEPTACLES CAMLOCKS Over Current Relay An over current relay Figure 11 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 Figure ...

Page 23: ...actor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 Three Phase Load When calculating the power requirements for 3 phase power use the following equation Aninadequatesizeconnectingcablewhichcannotcarrythe required load can ...

Page 24: ... Switch 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 7 Voltages Available UVWO Output Terminal Lugs Voltage Selector Switch 3 Phase 240 139V Position Voltage Selector Switch 3 Phase 480 270V Position 3Ø Line Line 208V 220V 240V 416V 440V 480V 1Ø Line Neutral 120V 127V 139...

Page 25: ...ion on the voltage selector switch Figure 13 Voltage Selector Switch 240 3Ø Position AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 14 in theW U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the ACVoltmeter Gauge Figure 15 Figure 14 ACVoltmeter Change Over Switch Figure15 ACVoltmeterGauge VoltreadingonW ULug AC Amm...

Page 26: ... Figure 18 Figure 18 Voltage Selector itch 3Ø 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 19 Figure 19 UVWO Terminal Lugs 3Ø 240 1Ø 139 Connections 3 Turn the voltage regulator knob Figure 20 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage i...

Page 27: ...connections to the UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire 1Ø 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1Ø 240 120 position as shown in Figure 24 Figure 24 Voltage Selector itch 1Ø 240 120V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 25 Figure 25 UVWO Terminal Lugs 1Ø 240 120V...

Page 28: ...refill with the specified amount of oil as outlined in the John Deere Owner s Manual Oil should be warm before draining Delo engine oil is the recommended engine oil for this generator When replacing engine oil please refill using Delo 400 LE SAE 15W 40 API CJ 4 engine oil Table 9 Recommended Motor Oil Fuel Check Refilling the Fuel System This generator has an internal fuel tank located inside the...

Page 29: ...AYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel ground 300 150 NOTICE ONLY use 2 diesel fuel ultra low sulfur diesel fuel when refueling FUEL TANK FILLER PORT DIESEL FUEL Figure 30 Full Fuel Tank Figure 31 Fuel Expansion DEF Ref...

Page 30: ...ists which can cause severe burns Table 10 Coolant Capacity Engine and Radiator 10 3 gal 39 liters Reserve Tank N A Table 11 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or deb...

Page 31: ...e terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the Auto Off Reset Manual itch is in either the AUTO or MANUAL position ALWAYS make sure that this itch is in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compound...

Page 32: ...rsonnel WARNING NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position MAIN CIRCUIT BREAKER GFCI CIRCUIT BREAKER AUXILIARY CIRCUIT BREAKER INCORRECT CORRECT Starting Manual 6 Place the Auto Off Reset Manual Switch in the MANUAL position to start the engine Figure 37 Figure 37 Auto Off Reset Manual Switch Manual Position 7 Once the engine starts l...

Page 33: ...193 586 kPa Figure 42 Oil Pressure Gauge 13 The coolant temperature gauge Figure 43 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 185 207 F 85 97 C PSI OIL PRESS 0 25 50 75 100 Figure 43 Coolant Temperature Gauge 14 The tachometer gauge Figure 44 will indicate the speed of the engine when the generator is operating Under normal op...

Page 34: ...ER attempt to perform any maintenance when the generator is in the auto mode 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 NOTICE When the Auto Off Reset Manual Switch is placed in the AUTO position the engin...

Page 35: ...Switch Figure 49 in the OFF RESET position Figure 49 Auto Off Reset Manual itch Off Reset 4 Verify that all status LEDs on the ECU control panel are OFF not lit 5 Remove all loads from the generator 6 Inspect entire generator for any damage or loosening of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in an emergency MAIN CIRCUIT BREAKER GFCI CIRC...

Page 36: ...0hrs Clean Inside of Fuel Tank 1000hrs Clean DEF Tank AsRequired Check Crankcase Ventilation Filter 4 1500hrs Replace Air Cleaner Elements 5 As Required Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X 1 During initial operation of a new engine change oil and filter between a minimum of 100 hrs and a maximum of 500 hrs Service interval depends on type of oi...

Page 37: ... Figure 51 Air Cleaner Indicator 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 NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air fil...

Page 38: ...seconds Try again if needed This unit is equipped with an automatic air bleeding system Check Oil Level 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 26 Replacing Oil Filter Remove the old oil filt...

Page 39: ...o 120 VAC 20 amp input receptacles located on the output terminal panel The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 55 To apply commercial power to these receptacles a power cord of adequate size will be required See Table...

Page 40: ...o oxidize the soot collected in the DPF Active regeneration requires assistance from the engine to help increase the heat level in the after treatment system Active regeneration occurs at a normal engine speed of 1800 rpm In addition active regeneration is initiated automatically by the Engine Control Module ECM timer based program every 96 hours This timer base program will reset at the end of an...

Page 41: ...rom the DPF is every 6 months 5000 hours Forced regeneration procedure Follow the steps below to initiate a forced regeneration 1 Verify that the AMBER pre alarm LED is ON or FLASHING and the DPF symbol is shown on the ECU display 2 Place all circuit breakers in the OFF position 3 Place the engine speed itch in the LOW position 4 Press the Program Exit button on the ECU controller and select FORCE...

Page 42: ...indicates the following Engine emissions are outside of normal operation range Sysyem fault has occured Figure 60 Engine Emissions System Malfunction Pre Alarm Series 800 Controller ECU Engine Started Shutdown Pre Alarm Alarm Acknowledge Screen Change Program Exit Option EESM NOTICE If the engine emissions system malfunction symbol Figure 60 is displayed during normal operation please contact your...

Page 43: ...ERY HIGH DPF Condition Regen Not Required Moderate Soot Level High Soot Level Very High Soot Level Service DPF Soot Only Pre Alarm Lamp N A N A Blinking ON ON Shutdown Lamp N A N A N A N A ON Engine Shutdown NOTICE Generator derating occurs during soot levels 4 and 5 Soot level 5 will cause the generator to shutdown If this condition occurs contact your nearest authorized service center NOTICE DO ...

Page 44: ...usting tool rotate the starwheel of the adjuster assembly to expand the brake shoes Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn Note Your trailer maybe equipped with drop spindle axles See axle manual for your axle type You will need a modified adjusting tool for adjusting the brakes in these axles With drop spindle axles a m...

Page 45: ...nents correct Replace and correct Dragging Brakes Brake lining thickness incorrect or not adjusted correctly Install new shoes and linings Enough brake fluid or correct fluid Replace rubber parts fill with dot 4 fluid NOTICE When replacing channel mounting hardware nuts bolts and washers NEVER substitute substandard hardware Pay close attention to bolt length and grade ALWAYS use manufacturer s re...

Page 46: ...f the trailer falling thus causing equipment damage and severe bodily harm even death DANGER When performing trailer inspection and maintenance activities you must jack up the trailer using jacks and jackstands When jacking and using jackstands place them so as to clear wiring brake lines and suspension parts i e springs torsion bars Place jacks and jackstands inside of the perimeter strip on the ...

Page 47: ...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 Lug NutTorque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the...

Page 48: ...e 48 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 Trailer Maintenance Figure 66 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts ...

Page 49: ...DCA150ssju4f 60 hz generator operation manual rev 0 11 0614 page 49 Trailer Wiring Diagram Figure 67 Trailer Towing Vehicle Wiring Diagram ...

Page 50: ...C D K B 3 V1 V1 1 2 3 4 CN7 1 2 41 98 CN8 CN11 Ar Fg ExAr ExFg AVR VR Re AS VS CB1 SW RY1 2 OC CT 1 2 3 SYMBOL DESIGNATION F A V MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTAT CURRENT TRANSFORMER CHANGE OVER SWITCH AMMETER AC AMMETER CHANGE OVER SWITCH VOLTMETER AC VOLTMETE...

Page 51: ...l rev 0 11 0614 page 51 Engine Wiring Diagram Figure 68 Engine Wiring Diagram D C B A G E F H J CN1 1 12 54 CN2 1 2 3 4 5 6 7 8 9 10 11 12 CN3 1 3 2 4 CN5 1 2 CN6 2 CN7 CN8 1 2 1 2 CN9 CN12 1 2 1 2 CN10 CN11 1 2 3 CN4 B1 ACC TERMINAL BOARD TB2 B2 ...

Page 52: ...tmeter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 19 ohms across J K on CN1 Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Outpu...

Page 53: ...u Screen will be displayed on the ECU controller 4 Releasing the Hour Check Button and pushing the Program Exit Button on the ECU controller will return the controller to the main screen HOUR CHECK BUTTON 5 Push the Program Exit Button on the ECU controller and select the Fault Diagnostics mode This mode enables the ability to carry out the fault diagnostics as listed below DM1 Active Faults Displ...

Page 54: ...oes not guarantee the availability of the parts listed 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 QtY column 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 A blank entry ...

Page 55: ...RY 6 RE539279 FILTER OIL CARTRIDGE 3 P537876 ELEMENT AIR CLEANER primary 3 P537877 ELEMENT AIR CLEANER safety 1 0601870440 CIRCUIT BREAKER 1P 20A S N 7601039 AND BELOW 1 0601808803 CIRCUIT BREAKER 1P 20A S N 7601040 AND ABOVE 1 0601870441 CIRCUIT BREAKER 2P 50A S N 7601039 AND BELOW 1 0601808804 CIRCUIT BREAKER 2P 50A S N 7601040 AND ABOVE 2 LY2DUS12VDC RELAY 1 0601806643 FUSE 15A 1 Y0601806647 FU...

Page 56: ...page 56 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 GENERATOR ASSY ...

Page 57: ... 2 4 8131315202 END BRACKET 1 5 8101350013 FIELD ASSY EXCITER 1 6 0012110060 HEX HEAD BOLT 4 7 0042610000 WASHER LOCK 4 8 031110160 WASHER FLAT 4 REPLACES P N 0041210000 9 0010112035 HEX HEAD BOLT 6 10 0040012000 WASHER LOCK 6 11 031112230 WASHER FLAT 6 REPLACES P N 0041212000 12 8131310104 COVER BEARING 1 13 8131312204 GASKET BEARING 1 14 8131331003 COVER END BRACKET 1 15 0105050616 HEX HEAD BOLT...

Page 58: ...page 58 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 control panel ASSY ...

Page 59: ...ROLLER 1 9 Y0602120569 GAUGE UNIT ASSY 1 10 Y0601810170 PANEL LIGHT 12V 1 11 0027104020 MACHINE SCREW 2 11A OEMAA8 HEX NUT 2 REPLACES P N 0207004000 12 0601830710 PANEL LIGHT SWITCH 1 13 0601831205 PUSH BUTTON SWITCH RED 1 14 82608 TOGGLE ITCH 1 REPLACES P N 0601831340 15 Y0601807631 FREQUENCY METER 45 65 HZ 1 16 Y0601817036 AC AMMETER 0 300A 600A 5A 1 17 Y0601806947 AC VOLTMETER 1 18 0601840073 V...

Page 60: ...page 60 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 CONTROL BOX ASSY ...

Page 61: ...0 HEX HEAD BOLT 4 REPLACES P N 0016908020 14 Y0602201458 STARTER RELAY 1 15 011808015 MACHINE SCREW 2 REPLACES P N 0027106015 15A 0044808000 WASHER LOCK 2 15B Y0206508000 HEX NUT 2 15C 0043003000 WASHER LOCK 2 15D Y0206803000 HEX NUT 2 16 0601821370 RECTIFIER 1 REPLACES P N 0601823240 17 0027104020 MACHINE SCREW 1 18 LY2DUS12VDC RELAY DC12V 1 REPLACES P N 0601827656 18A PTF08A RELAY BASE 1 REPLACE...

Page 62: ...page 62 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 CONTROL BOX ASSY continued ...

Page 63: ...32 0027105015 MACHINE SCREW 4 33 0601823863 RELAY UNIT 12V 2 34 7538070 MACHINE SCREW 4 REPLACES P N 0027104015 35 M4213600104 STOPPER CONTROL PANEL 1 36 952404470 WASHER FLAT 1 REPLACES P N 0041206000 37 505015300 SNAP PIN 1 REPLACES P N 0605010502 38 0601812626 PLUG 1 39 0601812711 PINS 2 40 M9501400304 DECAL FUSE HOLDER 1 41 M3246703704 WIRE HARNESS GENERATOR 1 42 M3358200402 WIRE HARNESS ENGIN...

Page 64: ...page 64 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 engine AND Radiator ASSY ...

Page 65: ... AIR CLEANER PIPE 1 8 M3374200004 AIR CLEANER BRACKET 1 9 0016910025 HEX HEAD BOLT 2 10 RE549081 SURGE TANK 1 REPLACES P N Y0602010222 11 Y0016908016 HEX HEAD BOLT 4 12 Y0193602200 OVER FLOW HOSE 1 13 M3311400103 CAC PIPE HOT SIDE 1 14 Y0602015610 CAC HOSE 3 15 M3311400203 CAC PIPE COLD SIDE 1 16 RE292067 V BAND CLAMP 1 REPLACES P N Y0602325033 17 R529509 GASKET 1 REPLACES P N Y0602320206 18 06055...

Page 66: ...page 66 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 engine AND Radiator ASSY continued ...

Page 67: ... 1 42 0603300285 BULKHEAD ROCKNUT 1 43 0602021070 CAP 1 44 Y0605000462 RUBBER SUSPENSION 2 45 0030016000 HEX NUT 4 45A 0040016000 WASHER LOCK 4 46 M3314300104 CAC PIPE BRACKET 1 47 0602326063 U BOLT 2 48 M3311200204 RADIATOR BRACKET 1 49 M3311200304 RADIATOR BRACKET 1 50 Y0016908015 HEX HEAD BOLT 24 51 M3311301003 FAN SHROUD 1 52 M3311301103 FAN SHROUD 1 53 011008020 HEX HEAD BOLT 10 REPLACES P N ...

Page 68: ...06 14 output terminal ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8 RED 4 SUNBELT GREEN 9 DESERT TAN 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED ...

Page 69: ...00 WASHER LOCK 2 16 952404470 WASHER FLAT 2 REPLACES P N 0041206000 17 0080200005 E RING 2 18 M3454400003 TERMINAL COVER 1 19 012212045 HEX HEAD BOLT 2 REPLACES P N 0010112045 20 031112230 WASHER FLAT 6 REPLACES P N 0041212000 21 0605050060 CONICAL WASHER LOCK 2 22 0030012000 HEX NUT 2 23 M3236400204 COVER 1 24 011106015 HEX HEAD BOLT 8 REPLACES P N 0016906015 25 M1260700504 BRACKET CIRCUIT BREAKE...

Page 70: ... output terminal ASSY CONTINUED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8 RED 4 SUNBELT GREEN 9 DESERT TAN 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED ...

Page 71: ...8070 MACHINE SCREW 2 REPLACES P N 0027104015 34 0603306775 BLIND PLUG 2 35 7538070 MACHINE SCREW 4 REPLACES P N 0027104015 36 0019208020 HEX HEAD BOLT 1 36A 0040508000 TOOTHED WASHER 1 37 M3237100204 INSULATING COVER 1 38 M4236400304 BRACKET 1 39 011106015 HEX HEAD BOLT 2 REPLACES P N 0016906015 40 M3236400004 CABLE OUTLET COVER 1 41 M3236300004 SUPPORTER CABLE OUTLET COVER 1 42 011206020 HEX HEAD...

Page 72: ...page 72 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 battery ASSY ...

Page 73: ...3000504 BATTERY BAND 1 3 0602220921 BATTERY BOLT SET 2 INCLUDES ITEMS W 3A WING NUT 2 3B PLASTIC WASHER 2 4 M9310500404 BATTERY SHEET 1 5 M2346900704 BATTERY CABLE 1 6 M3346901114 BATTERY CABLE 1 7 0017112025 HEX HEAD BOLT 1 7A 0040512000 TOOTHED WASHER 1 8 0016910025 HEX HEAD BOLT 1 8A 0040510000 TOOTHED WASHER 1 9 EARTH CABLE 1 MAKE LOCALLY ...

Page 74: ...page 74 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 muffler ASSY ...

Page 75: ...R300529 SEALING RING 1 REPLACES P N Y0602320203 12 Y0602325026 PIPE BAND 1 13 M3334100103 TAIL PIPE 1 13A Y0602311130 EXHAUST INSULATING WRAP 1 14 M3334000103 EXHAUST PIPE 1 14A Y0602311143 EXHAUST INSULATING MAT 1 15 RE289839 V BAND CLAMP 1 REPLACES P N Y0602325037 16 R528112 SEALING RING 1 REPLACES P N Y0602320202 17 0602326062 U BOLT 1 18 M3330400804 COVER EXHAUST PIPE 1 19 M3330400903 BRACKET ...

Page 76: ...page 76 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 fuel LINE ROUTING PLUMBING ASSY ...

Page 77: ...WHITE TEE FITTING 1 REPLACES P N Y0602022977 16 TY25141 COOLANT HOSE 2 REPLACES P N Y0379301300 17 Y0605515340 HOSE BAND 6 18 Y0602022585 90 ELBOW 1 19 0602022980 HOSE JOINT 1 20 TY22326 COOLANT HOSE 26 8 680 MM 3 1 PC 1 FT 21 TY22326 COOLANT HOSE 53 1 1350 MM 5 1 PC 1 FT 22 0605515198 HOSE BAND 4 23 0191300950 VENT HOSE 1 24 H216170 DEF TANK VENT FITTING 1 REPLACES P N Y0602330402 25 H216169 DEF ...

Page 78: ...page 78 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 fuel tank ASSY ...

Page 79: ...0108060 U NUT 2 REPLACES P N 0037908000 5A 0401450080 WASHER FLAT 2 REPLACES P N 0041208000 6 0191302300 SUCTION HOSE 1 7 0191302800 RETURN HOSE 1 8 Y0605515340 HOSE BAND 4 9 Y0602022577 90 ELBOW 1 10 Y0602022985 HOSE JOINT 2 11 M1363400104 DRAIN HOSE 1 12 0605515198 HOSE BAND 2 13 1502025103C DRAIN JOINT 1 REPLACES P N M9200000003 14 011206020 HEX HEAD BOLT 2 REPLACES P N 0016906020 15 0802011104...

Page 80: ...page 80 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 ENCLOSURE ASSY ...

Page 81: ... 1 6A M3491200104 ACOUSTIC SHEET 1 7 0019208020 HEX HEAD BOLT 22 8 M3424200203 OVER COVER FRONT FRAME 1 9 0019208020 HEX HEAD BOLT 15 10 M3434000302 CENTER FRAME 1 11 0010114040 HEX HEAD BOLT 4 11A 030214350 WASHER LOCK 4 REPLACES P N 0040014000 11B 031114260 WASHER FLAT 8 REPLACES P N 0041214000 11C 515455840 HEX NUT 4 REPLACES P N 0030014000 12 0010120050 HEX HEAD BOLT 4 12A 030220510 WASHER LOC...

Page 82: ...page 82 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 ENCLOSURE ASSY cont ...

Page 83: ...0605012309 DOOR HANDLE 1 30 0176060030 SELF LOCKING NUT 4 REPLACES P N 0207006000 31 M3464100102 ROOF PANEL 1 31A M3491600004 ACOUSTIC SHEET 1 32 0019208020 HEX HEAD BOLT 10 33 M3310600004 COVER 1 34 0019208020 HEX HEAD BOLT 4 35 M3464200102 ROOF PANEL 1 35A M3491600104 ACOUSTIC SHEET 1 36 0019208020 HEX HEAD BOLT 16 37 0017110025 HEX HEAD BOLT 4 REPLACES P N 0019210025 38 M3317100004 BRACKET SURG...

Page 84: ...page 84 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 ENCLOSURE ASSY cont ...

Page 85: ...COUSTIC SHEET 1 49 020108060 HEX NUT 39 REPLACES P N 0207008000 50 Y0605012309 DOOR HANDLE 7 51 0176060030 SELF LOCKING NUT 28 REPLACES P N 0207006000 52 0845046904 HINGE 5 REPLACES P N M9110100804 52A M9116100004 WASHER 5 53 0845047004 HINGE 6 REPLACES P N M9110100904 53A M9116100004 WASHER 6 54 0019208020 HEX HEAD BOLT 25 55 0601850097 STOPPER 8 56 0027208025 MACHINE SCREW 8 57 0845031504 BLIND ...

Page 86: ...page 86 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 rubber seals ASSY ...

Page 87: ... 1 3 Y0228901260 SEAL RUBBER 3 4 Y0228900690 SEAL RUBBER 1 5 Y0228900915 SEAL RUBBER 4 6 Y0228901115 SEAL RUBBER 4 7 Y0228901200 SEAL RUBBER 3 8 Y0228900630 SEAL RUBBER 1 9 Y0229400630 SEAL RUBBER 1 10 Y0228801050 SEAL RUBBER 2 11 Y0228800590 SEAL RUBBER 1 12 Y0228100560 SEAL RUBBER 2 13 Y0228100370 SEAL RUBBER 2 14 Y0222100165 RUBBER SHEET 2 15 Y0222100200 RUBBER SHEET 2 ...

Page 88: ...page 88 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 nameplate and decals ASSY ...

Page 89: ...IN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9503000004 DECAL WARNING ROTATING PART 2 M90300000 3 4 M9503000103 DECAL WATER OIL CHECK 1 M90300010 3 5 M9503100004 DECAL WARNING HOT COOLANT 1 M90310000 3 6 M9510100004 DECAL CAUTION HOT PARTS 1 M91010000 OUTPUTTERMINAL GROUP 4 1 M1550002203 DECAL RECEPTACLE CIRC BREAKER 1 M15000220 4 2 M9520000004 DECAL GROUND 2 M92000000 4 3 M952...

Page 90: ...page 90 dca150ssju4f 60 hz generator operation and Parts manual rev 0 11 06 14 nameplate and decals ASSY cont ...

Page 91: ...CLOSURE GROUP 8 1 M9511200204 DECAL MQ 1 M91120020 8 2 0600500092 EMBLEM 1 8 2 0021106015 MACHINE SCREW 4 8 3 M3561100004 STRIPE 2 M3110000 8 4 M5560101604 STRIPE 2 M56010160 8 5 M4560100904 STRIPE 1 M46010090 8 6 M3561100203 STRIPE 2 M36110020 8 7 M4560100003 STRIPE 1 M46010000 8 8 M3561100104 STRIPE 1 M36110010 8 9 M3550002204 DECAL CAUTION 1 M35000220 8 10 M9512000004 DECAL SUPPORT HOOK 2 M9120...

Page 92: ...er products g Items purchased in kits h The sender will be notified of any material 7 received that is not acceptable Such material will be held for five 8 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 Credit on returned parts will be issued 9 at dealer net price at time of the original pur...

Page 93: ...DCA150ssju4f 60 hz generator operation manual rev 0 11 0614 page 93 notes ...

Page 94: ...sales multiquip co uk Tel 0161 339 2223 Fax 0161 339 3226 COPYRIGHT 2014 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 manu...

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MULTIQUIP Whisperwatt DCA150SSJU4F, Operation And Parts Manual

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