Multiquip DCA70USI2 User Manual

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OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA70USI2

60HZ GENERATOR

(ISUZU BJ4JJ1-XYGD-02 DIESEL ENGINE)

PARTS LIST NO. M2870400304C

Revision #0 (06/28/11)

To ﬁnd the latest revision of this

publication, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafﬁc Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 3

TABLE OF CONTENTS

DCA70USI2 Generator

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ......................................... 3

Table Of Contents .................................................... 4

Parts Ordering Procedures ...................................... 5

Safety Information ..............................................6-11

Speciﬁcations ........................................................ 12

Dimensions ............................................................ 13

Installation ............................................................. 14

Installation ............................................................. 15

General Information ............................................... 16

Major Components ................................................ 17

Generator Control Panel ........................................ 18

Engine Operating Panel....................................20-21

Output Terminal Panel Familiarization .............. 22-24

Load Application .................................................... 25

Generator Outputs ................................................. 26

How To Read AC Ammeter/AC Voltmeter Gauges 27

Output Terminal Panel Connections ................. 28-29

Inspection/Setup ............................................... 30-33

Generator Start-Up Procedure ........................ 34-35

Generator Shut-Down Procedures ........................ 36

Maintenance ..................................................... 37-39

Trailer Maintenance .......................................... 40-43

Trailer Wiring Diagram ........................................... 44

Generator Wiring Diagram ..................................... 45

Engine Wiring Diagram .......................................... 46

Troubleshooting (Generator) .................................. 47

Troubleshooting (Diagnostic Lamp) ....................... 48

Component Drawings

Generator Assy. ................................................ 52-53

Control Box Assy. .............................................. 54-59

Engine And Radiator Assy. ............................... 60-63

Output Terminal Assy. ....................................... 64-65

Battery Assy. ..................................................... 66-67

Mufﬂer Assy. ..................................................... 68-69

Fuel Tank Assy. ................................................ 70-71

Enclosure Assy. ................................................ 72-77

Rubber Seals Assy. ...........................................78-79

Nameplate And Decals Assy. ...........................80-81

Terms And Conditions Of Sale — Parts ................ 82

Explanation Of Code In Remarks Column............. 50

Suggested Spare Parts ......................................... 51

PAGE 4 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

If you have an MQ Account, to obtain a Username

Effective:

Choose from three easy options:

January 1st, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

and Password, E-mail us at: parts@multiquip.

com.

To ob ta i n an MQ Acc oun t, con ta ct yo ur District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

When ordering parts, please supply:

❒ 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

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Truck

■ Ground

■ Next Day

■ Second/Third Day

www.multiquip.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 5

SAFETY INFORMATION

Do not operate or service the equipment before reading the

Potential hazards associated with the operation of this

entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally 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

equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Indicates a hazardous situation which, if not avoided,

COULD result in DEATH or SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 6 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

ensure generator is on level ground before use.

keep the machine in proper running condition.

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel

CAUTION

 NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This equipment should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modiﬁ cations. Unauthorized equipment modiﬁ cation will void all warranties.

 NEVER disconnect any

These devices are intended for operator safety.

devices will void all warranties.

CAUTION

 NEVER lubricate components or attempt service on a

running machine.

NOTICE

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 7

ENGINE SAFETY



NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

Wet stacking is a common problem with diesel engines

no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow

In order for a diesel engine to operate at peak efﬁ ciency,

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

applied to relieve the condition. It can reduce the system

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed

from the engine exhaust. Spark arresters are qualiﬁ ed

SAFETY INFORMATION

DANGER

 The engine fuel exhaust gases contain poisonous carbon

monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

 DO NOT place han d s or fingers inside en g ine

compartment when engine is running.

 NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

 DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

 NEVER

frequently to prevent engine malfunction.

 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.



which are operated for extended periods with light or

unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

 State Health Safety Codes and Public Resources

 DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

PAGE 8 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

to prevent accidental discharge of sparks or ﬂ ames

and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

FUEL SAFETY

DANGER

 Make sure the hitch and coupling of the towing vehicle

NEVER

tow a trailer with defective hitches, couplings, chains, etc.

Trailer tires should be inﬂ ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,

Trailer should be adjusted to a level position at all times

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

SAFETY INFORMATION

are rated equal to, or greater than the trailer “gross vehicle weight rating.”

 DO NOT start the engine near spilled fuel or combustible

ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

 ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

 ALWAYS use extreme caution when working with

ﬂ ammable liquids.

 DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

 DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

 NEVER use fuel as a cleaning agent.

 DO NOT smoke around or ne a r the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

TOWING SAFETY

 Check with your local county or state safety

towing regulations, in addition to meeting

Depar tment of Transpor tation (DOT) Safety Towing Regulations, before towing

your generator.

 Refer to MQ Power trailer manual for additional safety

information.

 In order to reduce the possibility of an accident while

transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.

 ALWAYS shutdown engine before transporting

CAUTION

 ALWAYS inspect the hitch and coupling for wear.

 Check the tire air pressure on both towing vehicle and

trailer. Also check the tire tread wear on both vehicles.

 ALWAYS make sure the trailer is equipped with a

chain.

 ALWAYS properly

vehicle.

 ALWAYS

backup, brake and trailer lights are connected and working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



or jack-kniﬁ ng. Smooth, gradual starts and stops will improve towing.

 Avoid sharp turns to prevent rolling.



when towing.

 Raise and lock trailer wheel stand in up position when

towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 9

ELECTRICAL SAFETY

DANGER



 Make sure power cables are securely connected to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

SAFETY INFORMATION

generator’s output receptacles. Incorrect connections may cause electri cal sh ock and damage to the generator.

NOTICE

 ALWAYS

The electr ical vol tage require d to

operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

NEVER insert any objects into the output

receptacles during op era tion. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water while AC power from the

generator is being transferred to a load.

 NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

PAGE 10 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

SAFETY INFORMATION

BATTERY SAFETY

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

DANGER

 DO NOT drop the battery. There is a possibility that the

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

WARNING

 ALWAYS wear safety glasses when handling

the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.

 ALWAYS keep the battery charged. If the battery is not

charged, combustible gas will build up.

 ALWAYS recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration of combustible gasses.

NOTICE

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to

dispose of hazardous waste.

 DO NOT

down a drain or into any water source.

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

 If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 11

SPECIFICATIONS

Table 1. Generator Speciﬁcations

Model

Type

Armature Connection Star with Neutral Zigzag

Phase

Standby Output

Prime Output

77 kVA (62 kW) 44 KW

70 kVA (56 KW) 40 KW

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

3 Single

DCA-70USI2

Voltage

Frequency

Speed

Power Factor

Aux. AC Power

Voltage

Output

Weight (No Fuel)

Weight (Fuel)

Maximum Lifting Capacity

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

240 or 480V 240 or 120V

60 Hz

1800 rpm

0.8 1.0

Single Phase, 60 Hz

120V

4.8 Kw (2.4 kW x 2)

3,771 lbs. (1,710 kg)

4,553 lbs. (2,065 kg)

14,050 lbs. (6,370 kg)

Table 2. Engine Speciﬁcations

ISUZU BJ-4JJ1XYGD-02 Tier 3

4 cycle, water-cooled, direct injection, turbo-charged

air to air intercooled

4 cylinders

3.76 in. x 4.13 in. (95.4 mm x 105 mm)

183 cu. in. (3,000 cc)

87.4 HP/1800 RPM

Electric

3.57 gal. (13.5 liters)

3.96 gal. (15.0 liters)

#2 Diesel Fuel

103 gal. (390 liters)

4.1 gal. (15.4 L)/hr at full load 3.1 gal. (11.9 L)/hr at 3/4 load

2.1 gal. (8.10 L)/hr at 1/2 load 1.3 gal. (4.80 L)/hr at 1/4 load

12V 72Ah x 1

PAGE 12 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

DIMENSIONS

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 30.10 in. (790 mm.) F 105.1 in. (2,670 mm.)

B 30.20 in. (766 mm.) G 68.30 in. (1,735 mm.)

C 30.20 in. (766 mm.) H 37.40 in. (950 mm.)

D 30.20 in. (766 mm.)

E 30.20 in. (766 mm.)

Dimension in. (mm) Reference Letter Dimension in. (mm)

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 13

INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

GENERATOR GROUNDING

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and speciﬁes that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm2)

b. Aluminum - 6 AWG (8.4 mm2)

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremel y poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set ﬁrmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the ﬂoor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

3. NEC article 250-52(c) speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 15

GENERAL INFORMATION

GENERATOR

This generator (Figure 3) is a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

ENGINE OPERATING PANEL

The “Engine Operating Panel” is provided with the following:

 Tachometer  Water Temperature Gauge  Warning Lamp  Fuel Leak Detected Alam Lamp  Pre-Heat Lamp  Oil Pressure Gauge  Charging Ammeter Gauge  Fuel Level Gauge  Panel Light/Panel Light Switch  ECU Controller  Engine Speed Switch

GENERATOR CONTROL PANEL

The “Generator Control Panel” is provided with the following:

 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltmeter Change-Over Switch  Voltage Regulator  3-Pole, 175 amp Main Circuit Breaker  “Control Box” (located behind the Gen. Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

• Voltage Selector Switch

OUTPUT TERMINAL PANEL

The “Output Terminal Panel” is provided with the following:

 Three 120/240V output receptacles (CS-6369), 50A  Three auxiliary circuit breakers, 50A  Two 120V output receptacles (GFCI), 20A  Two GFCI circuit breakers, 20A  Five output terminal lugs (3Ø power)

OPEN DELTA EXCITATION SYSTEM

This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectiﬁed and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the conﬁguration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “ﬁxed ceiling” and responds according the demands of the required load.

ENGINE

This generator unit incorporates an ISUZU BJ-4JJ1X diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 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.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

PAGE 16 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

MAJOR COMPONENTS

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Mufﬂer Assembly

2 Engine Assembly

3 Enclosure Assembly

4 Generator Assembly

5 Output Terminal Assembly

6 Battery Assembly

7 Fuel Tank Assembly

8 Generator Control Panel Assembly

9 Engine Operating Panel Assembly

Figure 3. Major Components

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 17

GENERATOR CONTROL PANEL

AUTO

MANUAL

OFF/RESET

LOW OILPRESSURE HIGH COOLANTTEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

1000

2000

3000

RP M

Figure 4. Generator Control Panel

The deﬁnitions below describe the controls and functions of the Generator Control Panel (Figure 4).

1. Voltage Regulator Control — Allows ±15% manual

adjustment of the generator’s output voltage.

2. Main Circuit Breaker—This three-pole, 175A main

breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.

INCREASE

DECREASE

OFF

V-W

W-U

U-V

OFF

Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.

The Control Box is equipped with the following major components:

 Over-Current Relay

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. This switch does not effect the generator output in any fashion, it is for current reading only.

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. AC Voltmeter — Indicates the output voltage present

at the U,V, and W Output Terminal Lugs.

6. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by the ammeter phase-selector switch.

7. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz.

 Automatic Voltage Regulator (AVR)

 Starter Relay

 Current Transformer

 Voltage Selector Switch

 Main Circuit Breaker

NOTICE

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 175 amp main breaker.

To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

PAGE 18 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

NOTES

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 19

ENGINE OPERATING PANEL

OFF

W-U

V-W

U-V

DECREASE

INCREASE

1000

2000

3000

R P M

AUTO

MANUAL

OFF/RESET

LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

Figure 5. Engine Operating Panel

PAGE 20 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENGINE OPERATING PANEL

The deﬁnitions below describe the controls and functions of the Engine Operating Panel (Figure 5).

Panel Light — Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

2. Panel Light Switch — When activated will turn on control

panel light.

3. Oil Pressure Gauge — During normal operation this

gauge should read between 42 ~71 psi. (290~490 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

4. Water Temperature Gauge — During normal operation this

gauge be should read between 167°~203°F (75° ~95°C

5. Charging Ammeter Gauge — Indicates the current

being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6. Fuel Gauge — Indicates amount of diesel fuel available.

7. Tachometer — Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8. Preheat Lamp — As the engine cranks, this lamp will

illuminate to indicate automatic preheating of the engine glow plugs. When the lamp turns off, this indicates that the preheat cycle is complte and the engine will start automatically.

9. Warning Lamp — This lamp will illuminate when a critical

engine fault has occured.

10. Fuel Leak Detected Alarm Lamp — This lamp will

illuminate when fuel level is low (25.5 gal/98 liters)

11. Engine Speed Switch — This switch controls the speed

of the engine (low/high).

12. Auto START/STOP Engine Controller (ECU) — This

controller has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault) has be en dete cted. When a fault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator. During cranking cycle, the ECU will attempt to crank the engine for 10 seconds before disengaging.

If 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 controller will shutdown the engine by initializing the Over Speed Protection mode.

Also the engine controller will shut down the engine in

the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

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. When this switch is set to the manual position, the generator will start immediately.

If the generator is to be connected to a building’s

AC power source via an automatic transfer switch (isolation), place the switch in the AUTO position. In this position, should an outage occur, the automatic transfer switch (ATS) will star t the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

B. Low Oil Pressure — Indicates the engine pressure

has fallen below 15 psi (103 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.

C. High Coolant Temperature — Indicates the engine

temperature has exceeded 230°F (110°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.

D. Overcrank Shutdown — Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a major fault.

E. Overspeed Shutdown — Indicates the engine is

running at an unsafe speed. This is considered a major fault.

F. Engine Running — Indicates that engine is running

at a safe operating speed.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 21

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 6) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds.

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel ” (Figure 6) is provided with the following:

 Three 120/240V output receptacles @ 50 amp

 Three Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two GFCI Circuit Breakers @ 20 amps

 Five Output Terminal Lugs ( U, V, W, O, Ground)

Figure 6. Output Terminal Panel

PAGE 22 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 10). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

Figure 7. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 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 selector switch is placed in the single-

phase 240/120 position.

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 10. Plastic Face Plate

(Output Terminal Lugs)

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 23

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 175A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An over current relay (Figure 12) 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 12. Over Current Relay

Figure 11. Connecting Loads

PAGE 24 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732.

NOTICE

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. SeeTable 6.

Table 5. Power Factor 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

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

 When connecti ng a resistance load such as an

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

 When connecting a ﬂuorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

 When connecting an electric drill or other 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.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 25

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 13). To obtain some of the voltages as listed in Table 7 (see below) will require a ﬁne adjustment using the voltage regulator (VR) control

knob located on the control panel.

Voltage Selector Switch

The voltage selector switch (Figure 13) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Figure 13. Voltage Selector Switch

Generator Amperage

Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed..

Table 8. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt

1Ø 240 Volt

3Ø 240 Volt 168 amps

3Ø 480 Volt 84 amps

155.5 X 2 amps (4 wire) 168 amps X 2 (Zigzag)

78.8 amps (4 wire) 168 amps (Zigzag)

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the three twist lock auxiliary receptacles.

Table 9 and Table 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch, press and hold the red button located at the bottom of the 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

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

1Ø Line-Neutral/

Line-Line

Voltage Selector Switch

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

Voltage Selector Switch Single-Phase 240/120V Position

120V

Line-Neutral

N/A N/A

Voltage Selector Switch

3-Phase 480/270V Position

240V

Line-Line

N/A N/A

Table 9. 1Ø GFCI Receptacle Load Capacity

KW in Use

Twist Lock (C6369)

1Ø 240/120V

40.4 0

39.2 5 amps/receptacle

38.0 10 amps/receptacle

38.6 15 amps/receptacle

35.6 20 amps/receptacle

Table 10. 3Ø Generator Maximum Amps

KVA in Use

(UVWO Terminals)

3Ø 240/480V

65.8

61.7

57.5

53.4

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

0 amps/receptacle

5 amps/receptacle

10 amps/receptacle

15 amps/receptacle

20 amps/receptacle

PAGE 26 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

GENERATOR OUTPUTS/GAUGE READING

HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

Before taking a reading from either gauge, set the Voltage Selector Switch (Figure 14) to the position which produces the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/139V position on the voltage selector switch).

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 17) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 18). This process can be repeated for terminals V and W.

Figure 17. AC Ammeter

Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 18. AC Ammeter

(Amp Reading on U Lug)

Figure 14. Voltage Selector Switch

240/139V 3

Ø Position

NOTICE

For 3Ø 208V/1Ø,120V, place the Voltage Selector Switch in the 3 Phase 240/139 position.

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 15) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 16)

Figure 15. AC Voltmeter

Change-Over Switch

Figure 16. AC Voltmeter

Gauge

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 27

OUTPUT TERMINAL PANEL CONNECTIONS

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 19..

3. Turn the voltage regulator knob (Figure 21) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required.

Figure 21. Voltage Regulator Knob

3Ø-208V/1Ø-120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure Figure 22.

Figure 19. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure Figure 20.

Figure 20. UVWO Terminal Lugs

3Ø-240/139V Connections

Figure 22. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 23. UVWO Terminal Lugs

3Ø-208/1Ø-120V Connections Connections

NOTICE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V..

PAGE 28 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480/277V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 24.

Figure 24. Voltage Selector Switch

3Ø-480/277V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

1Ø-240/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26.

Figure 26. Voltage Selector Switch

1Ø-240/120V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

Figure 25. UVWO Terminal Lugs

3Ø-440/254V Connections

3. Turn the voltage regulator knob (Figure 27) clockwise

Figure 27. UVWO Terminal Lugs

1Ø-240/120V Connections

to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required.

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a ﬁre.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 29

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 175 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

LUBRICATION OIL

Fill 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 28) on the dipstick. See Table 11 for proper selection of engine oil.

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause a ﬁre or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 29). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

Figure 28. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and reﬁll with the speciﬁed amount of oil as outlined in the ISUZU Engine Owner’s Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

 API Service Classiﬁcation CC/SC  API Service Classiﬁcation CC/SD  API Service Classiﬁcation CC/SE  API Service Classiﬁcation CC/SF

Table 11. Recommended Motor Oil

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after ﬁlling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Figure 29. Internal Fuel Tank System

PAGE 30 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

INSPECTION/SETUP

Refueling Procedure:

WARNING

Diesel fuel and its vapors are dangerous

to your hea l th and th e surro unding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 30).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

2. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and ﬁll tank (Figure 31).

Figure 31. Fueling the Generator

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 32).

Figure 30. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel when refueling.

Figure 32. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 33).

Figure 33. Fuel Expansion

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 31

INSPECTION/SETUP

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

ISUZU recommends ISUZU antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the ISUZU Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

CLEANING THE RADIATOR

The engine may overheat if the radiator ﬁns become overloaded 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 negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect it in accordance with the ISUZU Engine Owner’s Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to insufﬁcient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the

ISUZU Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 34) when depressed with the thumb as shown below.

Table 12. Coolant Capacity

Engine and Radiator 3.57gal (13.5 liters)

Reserve Tank 2 quarts (1.9 liters)

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

Table 13. Anti-Freeze Operating Temperatures

Vol %

Anti-

Freeze

50 -37 -34 108 226

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Freezing Point Boiling Point

°C °F °C °F

Figure 34. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan while the generator set is running.

PAGE 32 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

INSPECTION/SETUP

BATTERY

This unit is of negative ground DO NOT connect in reverse. Always maintain battery ﬂuid level between the speciﬁed marks. Battery life will be shortened, if the ﬂuid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always kee p the ter minals fir mly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery is sufﬁciently charged if the speciﬁc gravity of the battery ﬂuid is 1.28 (at 68° F). If the speciﬁc gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position. ALWAYS make sure that the MPEC Control Switch is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

ALWAYS be sure the battery cables (Figure 35) are properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

Figure 35. Battery Connections

ALTERNATOR

The polarity of the alternator is negative grounding type. When an inver ted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 33

GENERATOR START-UP PROCEDURE

INCORRECT

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure

36) in the OFF position prior to starting the engine.

STARTING

1. Place the voltage selector switch in the desired voltage position (Figure 38).

Figure 38. Voltage Selector Switch

STARTING (MANUAL)

1. Place the engine speed switch (Figure 39) in the LOW (down) position.

Figure 36. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been

conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output terminal lugs as shown inFigure 11. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 37).

CORRECT

Figure 39. Engine Speed Switch (Low)

2. Place the MPEC control switch in the MANUAL

position to start the engine (Figure 40).

Figure 40. MPEC Control Switch

(Manual Position)

3. Depending on the temperature of the coolant (cold weather conditions), the pre-heat lamp (Figure 41) will light (ON) and remain on until the pre-heating cycle has been completed. After completion of the pre-heating cycle, the light will go OFF and the engine will start up automatically.

Figure 37. Engine Enclosure Doors

Figure 41. Pre-Heat Lamp

4. Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct

PAGE 34 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

GENERATOR START-UP PROCEDURE

the problem. If the engine is running smoothly, place the engine speed switch (Figure 42) in the HIGH (up) position.

Figure 42. Engine Speed Switch (High)

5. Verify that the engine running status LED on the MPEC module (Figure 43) is lit (ON) after the engine has started.

Figure 43. Engine Running (LED ON)

6. The generator’s frequency meter (Figure 44) should be displaying the 50 cycle output frequency in HERTZ.

9. The ammeter (Figure 47) will indicate zero amps with

no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 47. Ammeter (No Load)

10. The engine oil pressure gauge (Figure 48) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 42 to 71 psi. (290~490 kPa).

Figure 44. Frequency Meter

7. The generator’s AC-voltmeter (Figure 45) will display

the generator’s output in VOLTS..

Figure 45. Voltmeter Meter

8. If the voltage is not within the speciﬁed tolerance use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

Figure 48. Oil Pressure Gauge

11. The coolant temperature gauge (Figure 49) will

indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 167°~203°F (75°~95°C) (Green Zone).

Figure 49. Coolant Temperature Gauge

12. The tachometer gauge (Figure 50 will indicate the

speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 46. Voltage Adjust Control Knob

Figure 50. Engine Tachometer Gauge

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 35

GENERATOR SHUT-DOWN PROCEDURES

13. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 51).

Figure 51. Main, Aux. and GFCI

Circuit Breakers (ON)

14. Observe the generator’s ammeter (Figure 52) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

2. Place the engine speed switch (Figure 54) in the “LOW”

(down) position..

Figure 54. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the MPEC Control Switch (Figure 55) to the OFF/RESET position.

Figure 55. MPEC Control Switch (Off/Reset)

5. Verify that all status LEDs on the MPEC display are OFF (not lit).

Figure 52. Ammeter (Load)

15. The generator will run until manually stopped or an abnormal condition occurs.

WARNING

NEVER stop the engine suddenly except in an

emergency.

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 53 to the OFF position.

Figure 53. Main, GFCI and Load

Circuit Breakers (OFF

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

EMERGENCY SHUTDOWN PROCEDURE

1. Place the MPEC Control Switch (Figure 55) in the OFF/RESET position.

AUTOMATIC SHUT-DOWN SYSTEM

This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure, approximately 14 psi (97 kPa), or high water temperature, approximately 230° F (110° C), overspeed approximately +15%. The alarm lamps on the ECU illuminate to signify the reason for the shutdown.

NOTICE

Before inspecting generator, check that the Auto/ Manual switch is in the OFF/RESET position, and place all circuit breakers in the OFF position. Allow sufﬁcient time for adequate cooling. When ready to restart, complete all steps in the Generator Startup Procedure section of this manual.

PAGE 36 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

MAINTENANCE

Engine

Generator

10 Hrs

DAILY

250 Hrs 500 Hrs

Table 14. Inspection/Maintenance

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

Replace Engine Oil and Filter *

Clean Air Filter X

Check Fuel Filter/Water Separator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*

Replace Air Filter Element *

Check all Hoses and Clamps *

Clean Inside of Fuel Tank X

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

*1 Replace engine oil and ﬁlter at 100 hours, ﬁrst time only.

*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

*3 Replace primary air ﬁlter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,

with no sags or dips that could collect moisture and/or oil.

1000

Hrs

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 56) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 56) is attached to the air cleaner. When the air cleaner element is clogged, air intake

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be cleaned or reused.

restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 37

Figure 56. Air Cleaner/Indicator

MAINTENANCE

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.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 57) wash out any deposits or debris that have accumulated inside the fuel tank.

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel ﬁlter cartridge with new one every 500

hours or so.

 Loosen the drain plug at the lower top of the fuel ﬁlter.

Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

 Vent any air

AIR REMOVAL

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the ISUZU Engine Manual for details.

To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed.

Figure 57. Fuel Tank Cleaning

PAGE 38 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

MAINTENANCE

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 28.

Replacing Oil Filter

 Remove the old oil ﬁlter.

 Apply a ﬁlm of oil to the gasket on the new oil ﬁlter.

 Install the new oil ﬁlter.

 After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

FLUSHING OUT RADIATOR AND REPLACING COOLANT

 Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overﬂow tank and drain.

 Check hoses for softening and kinks. Check clamps for

signs of leakage.

 Tighten both cocks and replace the overﬂow tank.

 Replace with coolant as recommended by the engine

manufacturer.

 Close radiator cap tightly.

 Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

WARNING

Allow engine to cool when ﬂushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

RADIATOR CLEANING

The radiator (Figure 58) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling ﬁns or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the ﬁns and tube.

Figure 58. Radiator Cleaning

GENERATOR STORAGE

For long term storage of the generator the following is recommended:

 Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

 Completely drain the oil from the crankcase and reﬁll if

necessary with fresh oil.

 Clean the entire generator, internal and external.

 Cover the generating set and store in a clean, dry place.

 Disconnect the battery.

 Make sure engine coolant is at proper level.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 39

TRAILER MAINTENANCE

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below des cribe some of th e major components of a typical trailer that would be used with generator.

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.

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 — Measurement is from the ball hitch

to the rear bumper (reﬂector).

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 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 18 and FigureFigure 61 for lug nut tightening and sequence.

13. Axle — Indicates the maximum weight the axle can suppor t in pounds, and the diameter of the axle expressed in inches. Please note 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 shocks transmitted through the wheels. Types of suspension used are leaf, Q-ﬂex, and air ride.

5. Frame Width — Measurement is from fender to

fender

6. Jack Stand — Trailer support device with maximum

pound requirement from the tongue of the trailer.

7. Coupler — Type of hitch used on the trailer for

towing.

15. Electrical — Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application — Indicates which units can be employed on a particular trailer.

PAGE 40 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

TRAILER MAINTENANCE

BRAKES

Trailer 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.

Figure 59 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

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. Adjust, 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 7 on the remaining brakes.

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 59) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 59. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator 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 brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

Table 15. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Brake lining glazed? Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded? Correct weight.

Brake drums scored or grooved? Machine or replace.

Tire pressure correct? Inﬂate all tires equally.

Tires unmatched on the same axle? Match tires.

Brake components loose, bent or

broken?

Brake drums out-of-round? Replace.

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Brake lining thickness incorrect or

not adjusted correctly?

Enough brake ﬂuid or correct ﬂuid?

Replace components.

Install new shoes and

linings.

Replace rubber parts

ﬁll with dot 4 ﬂuid.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 41

TRAILER MAINTENANCE

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very impor tant 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

ALWAYS wear safet y glasses whe n

removing or installing force ﬁtted parts. Failure to comply may result in serious injury.

CAUTION

DO NOT attempt to repair or modify a

wheel. DO NOT install in 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.

Tire Wear/Inﬂation

Suspension

The leaf suspension springs and associated components (Figure 60) 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 17.

Figure 60. Major Suspension Components

Tire inﬂation pressure is the most important factor 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 wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Table 16. Tire Wear Troubleshooting

Wear Pattern Cause Solution

Center Wear Over inﬂation.

Edge Wear Under inﬂation.

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

Loss of camber or overloading.

Wheel lockup and tire skidding.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

Table 17. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-Bolt Min-30 Max-35

7/16" U-Bolt Min-45 Max-60

1/2" U-Bolt Min-45 Max-60

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.

Min-30 Max-50

PAGE 42 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

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 61). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as deﬁned by Table 18.

3. After ﬁrst road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

Table 18. Tire Torque Requirements

Wheel Size

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

TRAILER MAINTENANCE

Figure 61. Wheel Lug Nuts

Tightening Sequence

NOTICE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 43

TRAILER WIRING DIAGRAM

Figure 62. Trailer/Towing Vehicle Wiring Diagram

PAGE 44 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

GENERATOR WIRING DIAGRAM

Figure 63. Generator Wiring Diagram

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 45

ENGINE WIRING DIAGRAM

Figure 64. Engine Wiring Diagram

PAGE 46 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

CONTROLLER WIRING DIAGRAM

Figure 65. Engine Controller

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 47

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 19. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check for approximately 17.3 ohms across J & K on CN1

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

PAGE 48 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

TROUBLESHOOTING (DIAGNOSTIC LAMP)

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. Press the diagnostic button (Figure 66) on the diagnostic panel to determine if an engine malfunction has occurred.

Figure 66. Diagnostic Panel

METHOD OF OPERATION

1. Normally, the diagnostic lamp will be dimly lit when the MPEC Control Switch is placed in the MANUAL position.

2. If engine trouble occurs, the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position.

3. The diagnostic lamp will indicate that an engine malfunction has occurred.

NOTICE

For a complete understanding of error codes and troubleshooting procedures, refer to the enclosed engine instruction manual.

NOTICE

If the engine is cranked while the diagnostic switch is in the “ON” position, the engine will not be stopped even if the starter switch is turned to the “OFF” position. In such case, turn the diagnostic switch to the “OFF” position.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 49

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

QTY. Column

— Item quantity can be indicated by a

A/R (As Required) is generally used for hoses or other

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks”

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed

same unique symbol will be included when this item is

— Used to list an effective serial

— Indicates that the part

part is NOT used on a speciﬁc model or model number

available items. Examples include battery cables, shims,

— Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available

remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

Numbers Used

number, a blank entry, or A/R.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

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.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁed in the “Remarks” Column.

parts that are sold in bulk and cut to length.

Column.

REMARKS Column

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use

is used only with the speciﬁc model number or model number variant listed. It can also be used to show a

variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of

and certain washers and nuts.

“Not Sold Separately”

for sale through Multiquip.

PAGE 50 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

SUGGESTED SPARE PARTS

DCA70SSIU2 WHISPERWATT GENERATOR WITH ISUZU BJ-4JJ1XYGD-02 DIESEL ENGINE

1 to 3 units

QTY. P/N DESCRIPTION

5............8980188580 .......... CARTRIDGE , OIL FILTER

5............8981430410 .......... FILTER, FUEL, ELEMENT, MAIN

5............8980758551 .......... FILTER, FUEL, ELEMENT, PRE

5............8980742880 .......... FILTER, FUEL, ELEMENT

5............8980714010 .......... FILTER, FUEL, FEED PUMP

3............0602046365 .......... ELEMENT, AIR

1............8980388560 .......... BELT, FAN

1............M2310502203 ....... RADIATOR HOSE, UPPER

1............M2310502404 ....... RADIATOR HOSE, UPPER, SHORT

1............M2310502303 ....... RADIATOR HOSE, LOWER

1............8121468300 .......... SENSOR, WATER TEMP. (ENGINE SIDE)

1............8971256001 .......... SWITCH, WARNING, OVERHEAT (ENGINE SIDE)

1............8980274560 .......... SENSOR, OIL PRESSURE (ENGINE SIDE)

1............1096300850 .......... GASKET, SENSOR OIL PRESSURE (ENGINE SIDE)

1............0601870440 .......... CIRCUIT BREAKER, 1P, 20 AMP

1............0601870441 .......... CIRCUIT BREAKER, 2P, 50 AMP

1............0601806644 .......... FUSE, 30 AMP

1............0601806640 .......... FUSE, 65 AMP

3............0601806671 .......... FUSE, 15 AMP

1............0601820602 .......... AUTOMATIC VOLTAGE REGULATOR

1............0602122272 .......... UNIT, OIL PRESSURE

2............0601810245 .......... BULB, ALARM LAMP

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 51

GENERATOR ASSY.

PAGE 52 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B5110000402 ROTOR ASSY 1 1-1 FIELD ASSY 1 1-2 0601820083 RECTIFIER 3 1-3 0601822664 ZNR 1 1-4 B3120100804 HOLDER, ZNR 1 1-5 B3120100604 INSULATOR WASHER 3 1-6 B3120100604 INSULATOR WASHER 5 1-7 B3111100603 FAN 1

1-8 B2163100004 COUPLING DISK ......................... 3 .....PURCHASE ITEMS 1- THRU 1-9 AS A SET

1-9 0010304016 HEX HEAD BOLT 1 1-9A B2163700004 BALANCING WEIGHT 1 1-9B 0204004000 U-NUT 1 1-10 B3163200104 COUPLING WASHER 2 1-11 0342612030 HEX HEAD CAP SCREW 6 1-12 0046512000 WASHER, FLAT 6 1-13 0071906309 BEARING 1 2 0010310020 HEX HEAD BOLT 8 3 0042510000 WASHER, LOCK 8 4 B5130000303 STATOR ASSY 1 4-1 0845041904 GROMMET 2 5 B3137000803 FIELD ASSY EXCITER 1 6 0016008060 HEX HEAD CAP SCREW 4 7 0042508000 WASHER, LOCK 4 8 B3153000513 END BRACKET 1 9 0017108035 HEX HEAD BOLT 6 10 B3153400504 PACKING 1 11 B3153400404 COVER, BEARING 1 12 0017106016 HEX HEAD BOLT 3 13 0010310025 HEX HEAD BOLT 12 14 0042510000 WASHER, LOCK 12 15 B5131300004 COVER, END BRACKET 1 16 0340406040 HEX HEAD BOLT 1 17 0600815000 NUT 1 18 0041206000 WASHER, FLAT 1 19 B3131300804 COVER, END BRACKET 1 20 0029205012 MACHINE SCREW 4 21 0041205000 WASHER, FLAT 4 22 0605000413 RUBBER SUSPENSION 2 23 0030012000 HEX NUT 2 23A 0040012000 WASHER, LOCK 2 23B 0041212000 WASHER, FLAT 2

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 53

CONTROL BOX ASSY.

PAGE 54 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2213001512 CONTROL BOX 1 1-1 0330000180 EDGING 2 1-2 0330000610 EDGING 1 1-3 0330000045 EDGING 2 1-3 0330000120 EDGING 2 2 0601870432 CIRCUIT BREAKER, 175A 1 2-1 0601870490 COVER, CIRCUIT BREAKER 2 3 0021004040 MACHINE SCREW 4 4 0601823863 RELAY UNIT 2 5 0027104016 MACHINE SCREW 4 6 0601820602 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105016 MACHINE SCREW 4 8 0601801123 CURRENT TRANSFORMER 3 9 0027106020 MACHINE SCREW 6 10 0601820847 OVER CURRENT RELAY 1 11 0601820848 OVER CURRENT RELAY 1 12 0027104016 MACHINE SCREW 2 12A 0207004000 HEX NUT 2 13 M2260500204 SET PANEL, ELECTRIC PARTS 1 14 0016906016 HEX HEAD BOLT 4 15 0601802218 HOLDER, FUSE 1 15A 0601806671 FUSE, 15A 3 16 0027103016 MACHINE SCREW 1

17 LY20DC12V RELAY .........................................................2 ................REPLACES P/N 0601827656

17A PTF08A BASE ...........................................................2 ................REPLACES P/N 0601823109

17B PYCAT CLIP ............................................................4 ................REPLACES P/N 0601824400

18 0027104020 MACHINE SCREW 4 19 0601815153 TERMINAL 1 20 0027104016 MACHINE SCREW 2

21 8121468300 SENSOR, INLET AIR TEMP. .......................1 ................REPLACES P/N 0603210240

22 8980980660 CONTROLLER ............................................1 ................REPLACES P/N 0602202689

23 M3260500604 BRACKET 1 24 0016906016 HEX HEAD BOLT 4 25 0601831205 PUSH BUTTON SWITCH 1 26 0601831330 DIAGNOSTIC SWITCH 1 27 0016916016 HEX HEAD BOLT 4 28 0601823240 RECTIFIER 1 29 0027105020 MACHINE SCREW 1

30 8972177780 SENSOR, BAROMETRIC PRESSURE ......1 ................REPLACES P/N 0602130220

31 M2260600104 BRACKET, SENSOR 1 32 0027105016 MACHINE SCREW 2 33 0027105016 MACHINE SCREW 2

34 8944001061 RELAY, STARTER .......................................1 ................REPLACES P/N 0602202502

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 55

CONTROL BOX ASSY.

PAGE 56 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

35 8970119490 RELAY, GLOW PLUG ..................................1 ................REPLACES P/N 0602202685

36 0027105016 MACHINE SCREW 4

37 5825500290 RELAY .........................................................3 ................REPLACES P/N 0602201400

38 0027105016 MACHINE SCREW 3 39 M2213500604 CONTROL BOX COVER 1 40 0016906016 HEX HEAD BOLT 4 41 M2270100204 SECLECTOR SWITCH 1 41A M2550001404 DECAL : SELECTOR SWITCH NO. 1 41B M2550001504 DECAL : SELECTOR SWITCH NO. 1 42 M2213602303 SWITCH BRACKET 1 42-1 0330000150 EDGING 2 43 M2213602404 SWITCH BRACKET 1 44 0027104035 MACHINE SCREW 4 44A 0207004000 HEX NUT 4 45 0027104016 MACHINE SCREW 4 45A 0207004000 HEX NUT 4 46 0016906016 HEX HEAD BOLT 4 47 M2213602504 SWITCH COVER 1 48 0016906016 HEX HEAD BOLT 6 49 M2213602604 SWITCH COVER 1 49-1 0228800175 SEAL RUBBER 1 49-2 0228800150 SEAL RUBBER 1 49-3 0317700180 SEAL RUBBER 1 50 0016906016 HEX HEAD BOLT 4 51 0016906016 HEX HEAD BOLT 12 51A 0040506000 TOOTHED WASHER 1 52 M2223001003 CONTROL PANEL 1 53 0601807641 FREQUENCY METER, 45~ 65Hz 240V 1 54 0601808987 AC AMMETER, 0~ 150A/300A : 5A 1 55 0601801040 CHANGE- OVER SWITCH, AMMETER 1 56 0601806859 AC VOLTMETER, 0~ 600V 1 57 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 58 0601840073 RHEOSTAT (VR), 2W 1K OHM 1 59 0601840121 KNOB 1 60 0602202641 CONTROLLER 1 61 0021004040 MACHINE SCREW 2 61A 0207004000 HEX NUT 2 62 0601831340 SWITCH 1 63 0602103092 ALARM LAMP 2 63A 0601810245 BULB, DC18V 2 64 0602120095 TACHOMETER 1 65 0602122093 OIL PRESSURE GAUGE 1 66 0602123090 WATER TEMPERATURE GAUGE 1 67 0602121081 CHARGING AMMETER 1

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 57

CONTROL BOX ASSY.

PAGE 58 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 68 0602125090 FUEL GAUGE 1 69 0601810141 PANEL LIGHT 1 70 0601831330 SWITCH, PANEL LIGHT 1 71 0601831395 SWITCH, ENGINE SPEED 1 72 M1224100104 STOPPER 1 73 0027105010 MACHINE SCREW 2 74 0027105010 MACHINE SCREW 4 75 M9220100004 SET SCREW 2 76 0080200007 SNAP RING 2 77 0602122272 UNIT, OIL PRESSURE 1 78 M9200100004 ADAPTER 1 79 0602120465 PICK UP, TACHOMETER 1 80 M2357202104 FUSE HOLDER UNIT 1 80A 0601806644 FUSE, 30A 1 81 0601806640 FUSE, 65A 1 82 M2246702304 WIRE HARNESS, GENERATOR 1 83 M2357201702 WIRE HARNESS, ENGINE 1 84 M2357201802 WIRE HARNESS, CONTROLLER 1

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 59

ENGINE AND RADIATOR ASSY.

PAGE 60 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2923200134 ENGINE, ISUZU BJ-4JJ1X 1

1A 8980388560 FAN BELT ....................................................1 ................REPLACES P/N 0602015254

1-1 8980188580 CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041222

2 0605000451 RUBBER SUSPENSION 2 3 M2413800104 COLLER 2 4 0030010000 HEX NUT 2 5 0040010000 WASHER, LOCK 2 6 0042810000 WASHER, FLAT 2 7 0602012773 RADIATOR 1 7-1 0602011079 CAP, RADIATOR 1 8 M9312200104 RUBBER MOUNT 2 9 0016906025 HEX HEAD BOLT 2 10 M2310502203 RADIATOR HOSE, UPPER 1 11 M2310502404 RADIATOR HOSE, UPPER, SHORT 1 12 M2310400104 RADIATOR PIPE 1 13 M2310502303 RADIATOR HOSE, LOWER 1 14 0605515147 HOSE BAND 4 15 M2923200124 INTER COOLER 1 16 0132004000 PLUG, 3/8" 1 17 0010510020 HEX HEAD BOLT 8 17A 0040010000 WASHER, LOCK 8 17B 0041210000 WASHER, FLAT 8 18 M2310502103 INTER COOLER HOSE 1 19 M2310503203 INTER COOLER HOSE 1 20 M2310400203 INTER COOLER PIPE 1 21 M2310501703 INTER COOLER HOSE 1 22 0605515208 HOSE BAND 3 23 0605515205 HOSE BAND 1 24 0605515207 HOSE BAND 3 25 0605515237 HOSE BAND 1 26 M2313300404 FAN BRACKET 1 27 0017110030 HEX HEAD BOLT 4 28 0601822798 FAN MOTOR 1 29 0017110030 HEX HEAD BOLT 4 30 0602046582 AIR CLEANER 1 30A 0602046365 ELEMENT, AIR CLEANER 1 31 0602040651 INDICATOR, AIR CLEANER 1 32 0602040554 AIR CLEANER BAND 1 33 0016908030 HEX HEAD BOLT 2 34 M2373101304 HOSE, AIR CLEANER 1 35 M2326100204 BLOWBY PIPE 1 36 M2373101204 HOSE, AIR CLEANER 1 37 M2373100603 HOSE, AIR CLEANER 1 38 0605515230 HOSE BAND 1 39 0605515230 HOSE BAND 2 40 0605515197 HOSE BAND 2

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 61

ENGINE AND RADIATOR ASSY. (CONTINUED)

PAGE 62 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 41 0191500680 BLOWBY HOSE 1 42 0605515149 HOSE BAND 2 43 M3326200204 BLOWBY HOSE BRACKET 1 44 001698020 HEX HEAD BOLT 1 45 M9602000003 DRAIN JOINT 1 46 M9200200004 PLUG 1 47 0150000018 O-RING 1 48 0016906020 HEX HEAD BOLT 2 49 0199901700 DRAIN HOSE 1 50 0199901400 DRAIN HOSE 1 51 0605515106 HOSE BAND 4

52 0602022581 ADAPTER....................................................1 ................S/N 8801630 AND BELOW

52 0602022581 ADAPTER....................................................1 ................S/N 8801631 AND ABOVE

53 0602022561 90° ELBOW .................................................1 ................S/N 8801630 AND BELOW

53 0602022561 90° ELBOW .................................................1 ................S/N 8801631 AND ABOVE

54 0603306590 CONNECTOR .............................................1 ................S/N 8801630 AND BELOW

54 0603306590 CONNECTOR .............................................1 ................S/N 8801631 AND ABOVE

55 0603300285 LOCKNUT ...................................................1 ................S/N 8801630 AND BELOW

55 0603300285 LOCKNUT ...................................................1 ................S/N 8801631 AND ABOVE

56 0605511395 VALVE .........................................................1 ................S/N 8801630 AND BELOW

56 0605511395 VALVE .........................................................1 ................S/N 8801631 AND ABOVE

57 0603306395 HOSE JOINT ...............................................1 ................S/N 8801630 AND BELOW

57 0603306395 HOSE JOINT ...............................................1 ................S/N 8801631 AND ABOVE

58 0602021070 CAP .............................................................1 ................S/N 8801630 AND BELOW

58 0602021070 CAP .............................................................1 ................S/N 8801631 AND ABOVE

59 0269200400 DRAIN HOSE ..............................................1 ................S/N 8801630 AND BELOW

59 0269200400 DRAIN HOSE ..............................................1 ................S/N 8801631 AND ABOVE

60 M9300000203 RESERVE TANK 1 61 0602010900 CAP, RESERVE TANK 1 62 M3316100303 BRACKET, RESERVE TANK 1 63 0016908020 HEX HEAD BOLT 2 64 0199101800 HOSE 1 65 0193600700 HOSE 1 66 0605515106 HOSE BAND 3 67 0603306798 PLUG 1/4" 1 68 8121468300 SENSOR, WATER TEMPERATURE 1 69 8971256001 SWITCH, WARNING OVERHEAT 1 70 8980274560 SENSOR, OIL PRESSURE 1 71 1096300850 GASKET, SENSOR OIL PRESSURE 1

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 63

OUTPUT TERMINAL ASSY.

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 GOLD

4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 64 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M3230700003 TERMINAL PANEL 1 2 M9220100304 OUTPUT TERMINAL BOLT 5 3 M9220100404 TIE BOLT 5 4 0039316000 HEX NUT 10 5 0040016000 WASHER, LOCK 15 6 0041416000 WASHER, FLAT 20 7 0016908035 HEX HEAD BOLT 5 8 M3236100803 TERMINAL COVER 1 9 M3236100404 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACNINE SCREW 4 11A 0030003000 HEX NUT 4 11B 0041203000 WASHER, FLAT 4 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601815194 TERMINAL 1 19 0027104016 MACHINE SCREW 2 20 0603306775 BLIND PLUG 2 21 0027104016 MACHINE SCREW 4 22 0601870440 CIRCUIT BREAKER, 1P 20A 2 23 0601870441 CIRCUIT BREAKER, 2P 50A 3 24 M1260700504 BREAKER FITTING COVER 1 24-1 0222100100 CUSHION RUBBER 2 25 0016906020 HEX HEAD BOLT 2 26 0601812598 RECEPTACLE, GF530EM 125V 20Ax2 2

27 0601812538 RECEPTACLE, CS6369 250V 50A .............3 ................S/N 8801630 AND BELOW

27 0601812538 RECEPTACLE, CS6369 250V 50A .............3 ................S/N 8801631 AND ABOVE

28 0027104016 MACHINE SCREW 10 28A 0207004000 HEX NUT 10 29 M2453400004 COVER 1 30 0016906016 HEX HEAD BOLT 6 31 M2236100603 TERMINAL COVER 1 32 0010112045 HEX HEAD BOLT 2 33 0041212000 WASHER, FLAT 2 34 M9310200004 STAY RUBBER 2 35 0030012000 HEX NUT 2 36 M4236100604 COVER 1 37 M4236400304 BRACKET 1 38 0019206015 HEX HEAD BOLT 2

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 65

BATTERY ASSY.

PAGE 66 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 0602220199 BATTERY 1 2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M2346900504 BATTERY CABLE 1 6 M2346900604 BATTERY CABLE 1

7 CABLE .........................................................1 ................MAKE LOCALLY

8 0017112025 HEX HEAD BOLT 1 8A 0040512000 TOOTHED WASHER 1 9 0016908025 HEX HEAD BOLT 1 9A 0040508000 TOOTHED WASHER 1

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 67

MUFFLER ASSY.

PAGE 68 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2330101103 MUFFLER 1 2 0017112030 HEX HEAD BOLT 4 3 M2333001403 EXHAUST PIPE 1 4 M2333200404 GASKET 1 5 0017110040 HEX HEAD BOLT 4 6 M2333200304 GASKET 1 7 0017110035 HEX HEAD BOLT 4 8 M2333001303 EXHAUST PIPE 1 9 0017110050 HEX HEAD BOLT 4

10 8943690210 GASKET ......................................................1 ................REPLAC ES P/N 0602320101

11 0039308000 U-BOLT 6

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 69

FUEL TANK ASSY.

PAGE 70 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2363000102 FUEL TANK 1 1-1 0605505070 CAP, FUEL TANK 1 1-2 0605501079 FUEL SENDER UNIT 1 1-2A 0605516090 GASKET 1 1-3 0027104016 MACHINE SCREW 2 M2363200704 TANK BAND 2 3 M2363200804 TANK BAND 3 4 M9310500104 SUPPORTER SHEET 6 5 0016908020 HEX HEAD BOLT 6 6 0207308000 HEX NUT 3 7 0222100710 TANK SHEET 5 8 0191302200 VENT HOSE 1 9 0605515109 HOSE BAND 2 10 M2323400103 FUEL FILTER BRACKET 1 11 0016910025 HEX HEAD BOLT 3 12 M2366700104 FUEL PUMP BRACKET 1 13 0016908020 HEX HEAD BOLT 2

14 8980139861 FUEL FILTER (MAIN) ..................................1 ................REPLACES P/N 0602042426

14A 8981430410 ELEMENT, FUEL FILTER, (MAIN) ..............1 ................REPLACES P/N 0602042515

15 8980758551 FUEL FILTER (PRE) ...................................1 ................REPLACES P/N 0602042405

15A 8980742880 ELEMENT, FUEL FILTER ............................1 ................REPLACES P/N 0602042516

16 8973834270 JOINT PIPE .................................................1 ................REPLACES P/N 0602042661

17 1096750951 JOINT BOLT ................................................4 ................REPLACES P/N 0602042621

18 1096300860 PACKING .....................................................8 ................REPLACES P/N 0602042641

19 0017108040 HEX HEAD BOLT 4 20 0010108080 HEX HEAD BOLT 2 20A 0040008000 WASHER, LOCK 2 20B 0041208000 WASHER, FLAT 2

21 8980682750 FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023240

21A 8980714010 FUEL FILTER ..............................................1 ................REPLACES P/N 0602042517

22 0016906025 HEX HEAD BOLT 2 23 0191300950 SUCTION HOSE 1 24 0191300740 SUCTION HOSE 1 25 0191300370 SUCTION HOSE 1 26 0191301580 SUCTION HOSE 1 27 0191300400 RETURN HOSE 1 28 0605515109 HOSE BAND 10

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 71

ENCLOSURE #1 ASSY.

PAGE 72 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2413002002 BASE 1 2 M2363300603 ENVIRONMENTAL TANK 1 3 0016908030 HEX HEAD BOLT 12 4 0603306797 PLUG 1 5 M2423001702 FRONT FRAME 1 5 M2493108503 FRONT FRAME 1 6 M2423002002 FRONT FRAME 1 6A M2493108503 ACOUSTIC SHEET 1 7 0601850265 GROMMET 1 8 0601850263 GROMMET 1 9 0601851777 GROMMET 1 10 0016908020 HEX HEAD BOLT 22 11 0016910025 HEX HEAD BOLT 6 12 M2310601003 HOSE COVER 1 13 M2310601104 HOSE COVER 1 14 0016906020 HEX HEAD BOLT 10 15 0016906020 HEX HEAD BOLT 2 16 M2423203604 DUCT COVER 2 17 0016906020 HEX HEAD BOLT 14 18 M2310200402 INTER-COOLER BRACKET 1 18A M2493600104 ACOUSTIC SHEET 1 19 0601851777 GROMMET 1 20 0016906020 HEX HEAD BOLT 14

21 M2310303204 FAN SHROUD .............................................1 ................S/N 8801475 AND BELOW

21 M2310303204 FAN SHROUD .............................................1 ................S/N 8801476 AND ABOVE

22 M2310303304 FAN SHROUD 1 23 M2310303404 FAN SHROUD 1 24 0016908020 HEX HEAD BOLT 9 25 0016906016 HEX HEAD BOLT 4

26 M2310302104 FAN GUARD ................................................1 ................S/N 8801475 AND BELOW

26 M2310302104 FAN GUARD ................................................1 ................S/N 8801476 AND ABOVE

27 M2310302204 FAN GUARD ................................................1 ................S/N 8801475 AND BELOW

27 M2310302204 FAN GUARD ................................................1 ................S/N 8801476 AND ABOVE

28 0016906016 HEX HEAD BOLT ........................................6 ................S/N 8801475 AND BELOW

28 0016906016 HEX HEAD BOLT ........................................6 ................S/N 8801476 AND ABOVE

29 M2423202803 COVER, FRONT FRAME 1 30 M2423202903 FRONT LOUVER 1 31 0019206016 HEX HEAD BOLT 6 32 0019208020 HEX HEAD BOLT 4 33 0019208020 HEX HEAD BOLT 4 34 M2433001003 CENTER FRAME 1

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 73

ENCLOSURE ASSY. #1 (CONTINUED)

PAGE 74 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENCLOSURE ASSY. #1 (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 35 0010114040 HEX HEAD BOLT 4 35A 0030014000 HEX NUT 4 35B 0040014000 WASHER, LOCK 4 35C 0041214000 WASHER, FLAT 8 36 0010120050 HEX HEAD BOLT 4 36A 0030020000 HEX NUT 4 36B 0040020000 WASHER, LOCK 4 36C 0041220000 WASHER, FLAT 8

37 M2463100402 ROOF PANEL 1

37A M2493505004 ACOUSTIC SHEET 1

38 M2463200702 ROOF PANEL 1

38A M2493502403 ACOUSTIC SHEET 1 39 M3463200704 BACK PLATE 2 40 0016906016 HEX HEAD BOLT 12 41 M2463200503 DUCT 1 41A M2493502704 ACOUSTIC SHEET 1 42 0016908020 HEX HEAD BOLT 10 43 M2463400103 DUCT COVER 1 44 0016908020 HEX HEAD BOLT 6 45 M2423203004 OVER-COVER, FRONT FRAME 1 45A M2493104404 ACOUSTIC SHEET 1 46 0019208020 HEX HEAD BOLT 38 47 0019210025 HEX HEAD BOLT 8 48 M3310600004 COVER, RADIATOR CAP 1 49 0019208020 HEX HEAD BOLT 4 50 M2483100404 COVER, EHAUST PIPE 1 51 0016908020 HEX HEAD BOLT 2 52 0016908020 HEX HEAD BOLT 1 52A 0040508000 TOOTHED WASHER 1 53 0605503062 FUEL LEAK DETECTED SWITCH 1 54 M1414800104 BRACKET 1 55 0016908020 HEX HEAD BOLT 2 56 M2357300004 HARNESS CLAMP 1 57 0016908020 HEX HEAD BOLT 2

58 M2310304604 FAN GUARD ................................................1 ................S/N 8801476 AND ABOVE

57 0016906016 HEX HEAD BOLT ........................................3 ................S/N 8801476 AND ABOVE

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 75

ENCLOSURE 2 ASSY.

PAGE 76 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

ENCLOSURE 2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M2443001202 REAR FRAME 1 1A M2493305103 ACOUSTIC SHEET 1 2 M2443301803 DUCT 2 2A M2493305904 ACOUSTIC SHEET 1 3 0016908020 HEX HEAD BOLT 12 4 0016910025 HEX HEAD BOLT 4 5 M2443305204 ACOUSTIC SHEET 1 6 0016908020 HEX HEAD BOLT 3 7 0016908020 HEX HEAD BOLT 3 8 M2443200503 DOOR, REAR FRAME 1 9 M1444600004 WINDOW PLATE 1 10 0037906000 U-NUT 8 10A 0041206000 WASHER, PLAIN 8 11 M9113000002 DOOR HANDLE ASSY. 1 12 0021806018 MACHINE SCREW 4 12A 0030006000 HEX. NUT 4 13 M9110100204 HINGE 2 14 M9116100004 WASHER 2 15 0019208020 HEX HEAD BOLT 3 16 M2453201802 SPLASHER PANEL 1 16A M2493405204 ACOUSTIC SHEET 1 17 0019108065 HEX HEAD BOLT 4 17A 0042308000 WASHER, LOCK 4 17B 0042408000 WASHER, FLAT 4 18 0016910025 HEX HEAD BOLT 2 19 M2453002703 SIDE DOOR 1 19A M2493409104 ACOUSTIC SHEET 1 20 M2453002603 SIDE DOOR 1 20A M2493409304 ACOUSTIC SHEET 1 21 M2453001903 SIDE DOOR 1 21A M2493405304 ACOUSTIC SHEET 1 22 M2453002503 SIDE DOOR 1 22A M2493409204 ACOUSTIC SHEET 1 23 M9113000002 DOOR HANDLE ASSY. 4 23A C9312500004 RUBBER SEAL 4 24 0021806016 MACHINE SCREW 16 24A 0030006000 HEX. NUT 16 25 M9110100804 HINGE 6 26 M9110100904 HINGE 5 27 M9116100004 WASHER 11 28 0019208020 HEX HEAD BOLT 26 29 0601850097 STOPPER 8 30 0027208025 MACHINE SCREW 8 31 M9310000004 CAP 13 32 0600800320 MANUAL PAK 1 33 0021806016 MACHINE SCREW 4

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 77

RUBBER SEALS ASSY.

PAGE 78 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229200840 SEAL RUBBER 1 2 0314502200 SEAL RUBBER 1 3 0229200950 SEAL RUBBER 3 4 0229200125 SEAL RUBBER 4 5 0228901165 SEAL RUBBER 1 6 0228900770 SEAL RUBBER 8 7 0228901105 SEAL RUBBER 3 8 0228900535 SEAL RUBBER 1 9 0228900475 SEAL RUBBER 1 10 0228100530 SEAL RUBBER 1 11 0228100870 SEAL RUBBER 1 12 0228101240 SEAL RUBBER 3 13 0228100800 SEAL RUBBER 1 14 0228100635 SEAL RUBBER 2 15 0228800525 SEAL RUBBER 1 16 0228800790 SEAL RUBBER 1 17 0228800475 SEAL RUBBER 1 18 0228100325 SEAL RUBBER 2 19 0228100420 SEAL RUBBER 2

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 79

NAMEPLATE AND DECALS ASSY.

PAGE 80 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1550000204 DECAL : NOTE ..........................................................1 ........... M15000020

2 M1550002203 DECAL : AUXILIARY OUTPUT .................................1 ........... M15000220

3 M2550000304 DECAL : NOTE ..........................................................1 ........... M25000030

4 M2550002103 DECAL : GENERATOR CONTROL ...........................1 ........... M25000210

5 M2550002203 DECAL : ENGINE OPERATING ................................1 ........... M25000220

6 M2550002303 DECAL : OPERATING PROCEDURES .....................1 ........... M25000230

7 M3550000004 DECAL : CAUTION ....................................................1 ........... M35000220

8 M9500000004 DECAL : OIL DRAIN PLUG .......................................1 ........... M90000000

9 M9500100004 DECAL : WATER .......................................................1 ........... M90010000

10 M9500100304 DECAL : INTER- COOLER DRAIN ...........................1 ........... M90010030

11 M9500300004 DECAL : - ..................................................................1 ........... M90030000

12 M9500300104 DECAL : + ..................................................................1 ........... M90030010

13 M9500500004 DECAL : DIESEL FUEL .............................................1 ........... M90050000

14 M9503000004 DECAL : WARNING MOVING PARTS .......................1 ........... M90300000

15 M9503000103 DECAL : WATER - OIL CHECK .................................1 ........... M90300010

16 M9503100004 DECAL : WARNING HOT COOLANT ........................1 ........... M90310000

17 M9503200004 DECAL : WARNING ENGINE EXHAUST ..................1 ........... M90320000

18 M9503200104 DECAL : DANGER EXHAUST GAS ..........................1 ........... M90320010

19 M9510000004 DECAL : FUEL DRAIN ..............................................1 ........... M91000000

20 M9510000104 DECAL : DOCUMENT BOX ......................................1 ........... M91000010

21 M9510100004 DECAL : CAUTION HOT PARTS ...............................1 ........... M91010000

22 M9510100304 DECAL: ENVIRONMENTAL WARNING ....................1 ........... M91010030

23 M9510100403 DECAL : CAUTION ....................................................1 ........... M91010040

24 M9520000004 DECAL : GROUND ....................................................1 ........... M92000000

25 M9520000104 DECAL : AMMETER CHANGE - OVER SWITCH .....1 ........... M92000010

26 M9520000204 DECAL : VOLTMETER CHANGE - OVER SWITCH ..1 ........... M92000020

27 M9520000504 DECAL : START CONTACT .......................................1 ........... M92000050

28 M9520000904 DECAL : DIAGNOSTIC SWITCH ..............................1 ........... M92000090

29 M9520001104 DECAL : DIAGNOSTIC BUTTON ..............................1 ........... M92000110

30 M9520100004 DECAL : WARNING ELECTRICAL SHOCK HAZ. .....2 ........... M92010000

31 M9520100204 DECAL : CAUTION ....................................................1 ........... M92010020A

32 M9520100304 DECAL : SAFETY INSTRUCTIONS ..........................1 ........... M92010030

33 M9520100404 DECAL : DANGER ....................................................1 ........... M92010040

34 M9520100503 DECAL : WARNING ...................................................1 ........... M92010050

35 M9520100603 DECAL : CAUTION ....................................................2 ........... M92010060

36 M9520200003 DECAL : CONNECTION OF OUTPUT CABLE .........1 ........... M92020000

37 M9520200404 DECAL : OVER CURRENT RELAY ...........................1 ........... M92020040

38 M9512200004 DECAL : MQ ..............................................................1 ........... M91220000

39 M9510200304 DECAL : MQ POWER 1 40 M2560101104 STRIPE 2 41 M2560100603 STRIPE : WHISPERWATT 2 40 M3560102204 STRIPE 2 43 M2560101303 STRIPE : 70 1 44 M2560101403 STRIPE : 70 1 45 M3560102504 STRIPE 2 46 0600500092 PLATE : MQ POWER 2 47 0021106016 MACHINE SCREW 4 48 M9520000804 DECAL : AC 1

49 M9504200004 DECAL : WARNING START FIRES, M9042000 ........ 1 ............S/N 8801496 AND ABOVE

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 81

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Parts must be in new and resalable 5.

Multiquip reserves the right to quote and

who use our products as integral parts of their

LIMITATIONS OF SELLER’S LIABILITY

connection with the sale of its products. Apart

statutory, which extend beyond the description

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be acc epted and credit will be allowed, subject to the following provisions:

A Retur ned Mate ria l Aut horizat ion 1. must be approved by Multiquip prior to shipment.

To obtain a Return Material Authorization, 2. a list must be provided to Multiquip Parts Sales that deﬁnes item numbers, quantities, and descriptions of the items to be returned.

A copy of the Return Material Authorization 3. must accompany the return shipment.

Freight is at the sender’s expense. All 4. parts must be returned freight prepaid to Multiquip’s designated receiving point.

The parts numbers and descriptions a. must match the current parts price list.

The list must be typed or computer b. generated.

The list must state the reason (s) c. for the return.

The list must reference the sales d. order ( s ) o r i n v o i c e (s ) u n d e r which the items were originally purchased.

The list must include the name e. and phone number of the person requesting the RMA.

co ndi tio n, in the ori gin al Mult iqu ip package (if any), and with Multiquip part numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a. price book and shows as being repl aced by another item, it is obsolete.)

Any parts with a limited shelf life b. (such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

Any line item with an extended c. dea l e r ne t pr i c e of le s s th a n $5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper products.g.

Items purchased in kits.h.

The sender will be notiﬁed of any material 7. received that is not acceptable.

Su ch mate ria l will be hel d 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 c h a s e, le s s a 15 % rest o c k i ng charge.

In cases where an item is accepted, for 10. which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

Credit issued will be applied to future 11. purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a speciﬁc date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

sell direct to Government agencies, and to Original Equipment Manufacturer accounts

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

Multiquip shall not be liable hereunder for damages in excess of the purchase price of the 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 other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warra nti es, expre ss or impli ed, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor author izes any person to assum e for it any other obligation or liability whatever in

from such writ ten statement of warranty, there are no warranties, express, implied or

of the products on the face hereof.

Effective: February 22, 2006

PAGE 82 — DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11)

NOTES

DCA70USI2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (06/28/11) — PAGE 83

OPERATION AND PARTS MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc trademarks are the property of their respective owners and used with permission.

This manual

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁcations, design or the information published in this publication at any time without notice and without incurring any obligations.

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Ofﬁce MQ Parts Department

18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

800-478-1244 Fax: 310-943-2238

Tel. (800) 421-1244 Fax (800) 537-3927

Fax: 310-537-4259 800-421-1244

800-427-1244 310-537-3700

310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

Fax: 310-943-2249

mexico United Kingdom

MQ Cipsa Multiquip (UK) Limited Head Ofﬁce

Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: pmastretta@cipsa.com.mx

Tel: (52) 222-225-9900 Fax: (52) 222-285-0420

Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinﬁeld, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk

Canada

Multiquip

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: jmartin@multiquip.com

Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664

Tel: 0161 339 2223 Fax: 0161 339 3226

, 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

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

Your Local Dealer is:

Multiquip DCA70USI2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual