Multiquip DCA150SSJU2 User Manual
PARTS AND OPERATION MANUAL
MQ POWER
DCA-150SSJU
DCA-150SSJU2
TM
WHISPERWATT
GENERATOR
© COPYRIGHT 2001, MULTIQUIP INC.
Parts List No. M3870300254
Revision #3 (09/07/01)
MULTIQUIP INC
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244 800-835-2551
FAX: 310-537-3927 FAX: 310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
..
. PARTS DEPARTMENT:
..
SERVICE DEPARTMENT:
PAGE 2 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN 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 DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help ............................................... 3
Table Of Contents ........................................................ 4
Parts Ordering Procedures .......................................... 5
Rules for Safe Operation .......................................... 6-9
Towing Rules for Safe Operation ............................... 10
Trailer Safety Guidelines ............................................ 11
Trailer Specifications ............................................ 12-13
Trailer Braking System ......................................... 14-15
Trailer Tires & Suspension .................................... 16-17
Trailer Wire Diagram ................................................... 18
Trailer Electric Brake Troubleshooting ........................ 19
Trailer Hydraulic Brake Troubleshooting ..................... 20
Operation and Safety Decals ................................ 21-22
DCA-150SSJU Specifications ................................... 23
MQPower DCA-150SSJUMQPower DCA-150SSJU
MQPower DCA-150SSJU
MQPower DCA-150SSJUMQPower DCA-150SSJU
AC GeneratorAC Generator
AC Generator
AC GeneratorAC Generator
General Information ................................................... 24
Major Components .................................................... 26
Dimensions ................................................................ 27
Control Panel Descriptions ................................... 28-29
Engine Operating Panel Description-
Engine Controller .................................................. 30-31
Engine Operating Panel Description-Ignition......... 32-33
Output Terminal Panel Descriptions ...................... 34-41
Installation ............................................................ 42-43
Pre Setup ............................................................. 44-47
Load Application ........................................................ 48
Generator Start-Up W/Key .................................... 49-51
Start-Up-Engine Controller/Manual ....................... 52-53
Start-Up Engine Controller/Auto ................................ 54
Generator Shut-Down Procedure ............................... 55
Maintenance ......................................................... 56-57
Engine Troubleshooting ......................................... 58-59
Engine Controller Troubleshooting .............................. 60
Generator Wiring Diagram .......................................... 61
Engine Wiring Diagrams ....................................... 62-63
Explanation of Code in Remarks Column .................. 64
Suggested Spare Parts ............................................. 65
Generator Assembly ............................................. 66-67
Control Box Assembly ........................................... 68-71
Engine & Radiator Assembly ................................. 72-77
Engine Operating Panel Assembly ........................ 78-81
Output Terminal Assembly ..................................... 82-83
Battery Assembly .................................................. 84-85
Muffler Assembly .................................................. 86-87
Fuel Tank Assembly .............................................. 88-89
Enclosure Assembly ............................................. 90-93
Rubber Seal Assembly .......................................... 94-95
Name Plate And Decals ........................................ 96-97
Terms and Condition of Sale — Parts ....................... 98
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
PARTS ORDERING PROCEDURES
■■
■ Dealer account number
■■
■■
■ Dealer name and address
■■
■■
■ Shipping address (if different than billing address)
■■
■■
■ Return fax number
■■
■■
■ Applicable model number
■■
■■
■ Quantity, part number and description of each part
■■
■■
■ Specify preferred method of shipment:
■■
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
•
Express account number)*
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■
UPS Ground Service at no charge for freight
■■
■■
■
PS Third Day Service at one-half of actual freight cost
■■
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
Extra Fax DiscountExtra Fax Discount
Extra Fax Discount
Extra Fax DiscountExtra Fax Discount
for Domestic USAfor Domestic USA
for Domestic USA
for Domestic USAfor Domestic USA
Dealers OnlyDealers Only
Dealers Only
Dealers OnlyDealers Only
UPS
Special
For faxed orders only
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 5
800/6-PARTS-7 • 800-672-7877
RULES FOR SAFE OPERATION
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by
trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-150SSJU portable generator:
GENERAL SAFETY
■
DO NOT operate or service this equipment before
reading this entire manual.
■
This equipment 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 the job.
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with
burns.
■
The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people. The generator engine gives off DEADLY carbon
monoxide gas.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
hot
components can cause serious
:
■
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■
NEVER operate this equipment under the
influence or drugs or alcohol.
■
NEVER use accessories or attachments,
which are not recommended by MQ Power for this
equipment. Damage to the equipment and/or injury to user
may result.
■
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
Always check the machine for loosened threads or bolts
before starting.
■
■
Always refuel in a well-ventilated area,
away from sparks and open flames.
■
Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT smoke around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe
Topping-off to filler port is dangerous, as it tends to spill
fuel.
bodily harm or even death.
PAGE 6 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
RULES FOR SAFE OPERATION
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
■
Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
:
NEVER touch output terminals during
operation. This is extremely dangerous.
Always stop the machine when contact with
the output terminals.
:
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Radiator
1. Radiator Cap - Removing the radiator cap while the
2. Coolant Drain Plug - Removing the coolant drain plug
3. Engine Oil Drain Plug - Removing the engine oil drain
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
:
Never use damaged or worn cables when
connecting power tools or equipment to the
generator. Make sure power connecting
cables are securely connected to the
generator’s output terminals, insufficient
tightening of the terminal connections may
cause damage to the generator and
electrical shock.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 7
RULES FOR SAFE OPERATION
Battery
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
injury to the eyes and skin. To avoid eye irritation, always
wear safety glasses. Use well insulated gloves when picking
up the battery. Use the following guidelines when handling
the battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.
:
■
Never over fill the battery with water above
the upper limit.
The battery contains acids that can cause
clothing or skin
, rinse skin or clothing
■
NEVER Run engine without air filter. Severe engine
damage may occur.
■
Always service air cleaner frequently to prevent carburetor
malfunction.
■
Always disconnect the battery before performing service
on the generator.
■
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
■
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
■
DO NOT leave the generator running in the manual mode
unattended.
■
DO NOT allow unauthorized people to operate this
equipment.
■
Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■
Refer to the
engine technical questions or information.
Loading and Unloading (Crane)
■
Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■
Always drain fuel prior to lifting.
■
Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
■
NEVER lift the machine while the engine is running.
John Deere Engine Owner's Manual
for
■
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
PAGE 8 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
Use adequate lifting cable (wire or rope) of sufficient
strength.
■
When lifting the 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 a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
Transporting
■
Always shutdown engine before transporting.
■
Tighten fuel tank cap securely.
■
Drain fuel when transporting generator over long distances
or bad roads.
■
Always tie-down the generator during transportation by
securing the generator.
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■
Always know the location of the nearest
and
first aid kit
Also know the phone numbers of the nearest
doctor
and
Maintenance Safety
■
NEVER lubricate components or attempt service on a
running machine.
. Know the location of the nearest telephone.
fire department
.
fire extinguisher
ambulance
,
RULES FOR SAFE OPERATION
■
Always allow the machine a proper amount of time to
cool before servicing.
■
Keep the machinery in proper running condition.
■
Fix damage to the machine immediately and always
replace broken parts.
■
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■
DO NOT use plastic containers to dispose of hazardous
waste.
■
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 9
DCA-150SSJU — TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
CAUTION :CAUTION :
CAUTION :
CAUTION :CAUTION :
Check with your county or state safety
towing regulations department before towing
your generator.
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure the trailer (Figure 1) that supports the generator
and the towing vehicle are in good operating condition and
both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
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. Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.
■
Place
rolling, while parked.
■
Place
prevent tipping, while parked.
■
Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■
Avoid sharp turns to prevent rolling.
■
Remove wheel stand when transporting.
■
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
underneath wheel to prevent
underneath the trailer’s bumper to
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
Figure 1. Generator with Trailer
PAGE 10 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — TRAILER-SAFETY GUIDELINES
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions while reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
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
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 for lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 3 on page 17). Please not that
some trailers have a double axle. This will be shown as
2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shock
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle. See page 16 for
proper wiring connections.
16. Application - Indicates which units can be employed
on a particular trailer.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 11
DCA-150SSJU — TRAILER-SPECIFICATIONS
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PAGE 12 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — TRAILER-SPECIFICATIONS
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 13
DCA-150SSJU — TRAILER BRAKING SYSTEM
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:
An electric brake system can be manually adjusted to
provide the corrected braking capability for varying road
and load conditions.
An electric brake system can be modulated to provide
more or less braking force, thus easing the brake load
on the towing vehicle.
An electric brake system has very little lag time between
the time the vehicle’s brakes are actuated and the
trailer’s brakes are actuated.
An electric brake system can provide an independent
emergency brake system.
Road testing is necessary in order to properly synchronize
the towing vehicle’s braking to the trailer’s braking. 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 adjustments can be
made, the trailer brakes should be burnished-in by applying
the brakes 20-30 times with approximately a 20 m.p.h.
decrease in speed, e.g. 40 m.p.h. to 20 m.p.h.. Allow ample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required. Refer to Table 5 for electric
brake troubleshooting guidelines.
Electric Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
8. Repeat steps 1 through 6 on the remaining brakes.
PAGE 14 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — TRAILER BRAKING SYSTEM
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. 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/surge brake
components that will require inspection and maintenance.
Inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section. Reference Table 6 for hydraulic brake
troubleshooting guidelines.
Figure 3. Hydraulic Brake Components
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 15
DCA-150SSJU — TRAILER TIRES & SUSPENSION
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing
the trailer wheels it is important the wheels, tires, and axle
are properly matched.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install an inner tube to
correct a leak through the rim. If the
rim is cracked, the air pressure in the
inner tube may cause pieces of the rim
to explode (break off) with great force and cause serious
eye or bodily injury.
Suspension
The leaf suspension springs and associated components
Tire Wear/Inflation
Tire inflation pressure is the most important factor in
preserving tire life. Pressure should be checked cold before
operation. DO NOT bleed air from tires when they are hot.
Check inflation pressure weekly to insure the maximum
tire life and to prevent premature tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
(Figure 4) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
PAGE 16 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
Figure 4. Suspension Components
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TLOB-U"2/106-XAM54-NIM
DCA-150SSJU — TRAILER TIRES & SUSPENSION
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SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
SNUG FIT ONLY.PARTS MUST ROTATE FREELY
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
-
RETAIN NUT
BOLT ASSEMBLY
.
05-XAM03-NIM
.
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO
NOT torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table
4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically for continued safe
operation.
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 17
ssaPdrihT
SBL-TF
Figure 5. Lug Nut Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-150SSJU — TRAILER WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — TRAILER-BRAKE TROUBLESHOOTING
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 19
eB.tsujdA
DCA-150SSJU — TRAILER-BRAKE TROUBLESHOOTING
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PAGE 20 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — GENERATOR DECALS
The DCA-150SSJU generator 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 appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 21
DCA-150SSJU — GENERATOR DECALS
PAGE 22 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — SPECIFICATIONS
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DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 23
DCA-150SSJU — GENERAL INFORMATION
DCA-150SSJU FAMILIARIZATION
Generator
The MQ Power Model DCA-150SSJU is a 120 kW
that is designed as 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.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
z
Tachometer
z
Water Temperature Gauge
z
Oil Pressure Gauge
z
Charging Ammeter Gauge
z
Engine Speed Switch
z
Auto/On/Off Engine Controller(if applicable)
z
Pre-Heat Button
z
Pre-Heat Lamp
z
Key Ignition starter
z
Fuel Gauge
z
Panel Light
z
Panel Light Switch
Generator Control Box
The “Generator Control Box” is provided with the following:
z
Output Voltage Adjustment Knob
z
Frequency Meter (Hz)
z
AC Ammeter (Amps)
z
AC Voltmeter (Volts)
z
Ammeter Change-Over Switch
z
Voltmeter Change-Over Switch
z
Main Circuit Breaker 400 amps
z
Over-Current Relay
z
Voltage Selector Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
z
Three 240 output receptacles, 50 amp
z
Two 120V output receptacles, 20 amp
z
3 Circuit Breakers 240V @50 amps
z
2 GFCI Circuit Breakers 120V@ 20amps
generator
Open Delta Excitation System
The DCA-150SSJU generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four leads: A, B, C and D. During light loads, the
power to the
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during 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 "
according the demands of the required load.
Engine
The DCA-150SSJU is powered by a 4 cycle, water cooled,
turbocharged John Deere 6081TF001 diesel
engine is designed to meet every performance requirement
for the generator. Reference Table 7, page 23 for engine
specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-150SSJU
generator are addressed on the following pages.
Electronic Governor System
The electronic governor system is made up of two parts, an
electronic controller that monitors frequency variation as the
load increases and decreases and an electronic actuator
that controls the engine throttle. The frequency is regulated
at ±0.25 to help protect sensitive equipment.Engine
Open-Delta
" excitation system. The open delta
Automatic Voltage Regulator
fixed ceiling
(AVR) is supplied
" and responds
engine. This
PAGE 24 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
NOTE PAGE
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 25
DCA-150SSJU
___
MAJOR COMPONENTS
Figure 6. Major Components
PAGE 26 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — DIMENSIONS
Figure 7. Dimensions
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 27
DCA-150SSJU — CONTROL PANEL
Figure 8. Control Panel
PAGE 28 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
DCA-150SSJU — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-150SSJU "
1. Main Circuit Breaker – This three-pole, 400 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.
2. AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
3. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
4. Voltmeter Change-Over Switch – This switch allows
the AC Voltmeter to indicate phase to phase voltage
between any two phases of the output terminals, or to
be switched off.
5. Voltage Regulator Control – Allows adjustment of the
generator’s output voltage.
Control Panel
" (Figure 8).
6. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 63Hz. with a calibration difference
of +0.5% with the mechanical governor or +0.25% with
the electronic governor.
7. AC Voltmeter – Indicates the single phase output
voltage present at the UVW terminals.
DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01) — PAGE 29
DCA-150SSJU — ENGINE OPERATING PANEL
S/N 7600091~
Figure 9. Engine Operating Panel
PAGE 30 — DCA-150SSJU — PARTS AND OPERATION MANUAL — REV. #3 (09/07/01)
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