Multiquip DCA85SSJU User Manual

PARTS AND OPERATION MANUAL

MQ POWER

DCA-85SSJU

TM

WHISPERWATT

GENERATOR

(STANDARD)

© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST No. M2872300104

Revision #2 (12/21/01)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail] • www:multiquip.com

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT:

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

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

MAIN

800/421-1244 or 310/537-3700
FAX: [phone]

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ............................................... 3

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

Rules for Safe Operation .......................................... 6-9

Towing Safety Precaution .......................................... 10

Trailer Safety Guidelines....................................... 11-17

Trailer Wiring Diagram ................................................ 18

Electrical Brake Troubleshooting ................................ 19

Hydraulic Brake Troubleshooting ................................ 20

Operation and Safety Decals................................ 21-22

DCA-85SSJU Specifications ..................................... 23

General Information ................................................... 24

Major Components .................................................... 25

Dimensions ................................................................ 26

Control Panel Descriptions ................................... 28-29

Engine Operating Panel Descriptions ................... 30-31

Output Terminal Panel Overview ........................... 32-39

Installation ............................................................ 40-41

Pre Setup ............................................................. 42-45

Load Application ........................................................ 46

Generator Start-up Procedure .............................. 47-49

Generator Start-up Procedure, Auto .......................... 50

Generator Shut-Down Procedure ............................... 51

Maintenance ......................................................... 52-53

Generator Wiring Diagram .......................................... 54

Engine Wiring Diagram .............................................. 55

Engine Troubleshooting ......................................... 56-57

Generator/Engine Troubleshooting ............................. 58

Engine Controller Troubleshooting .............................. 59

Explanation of Code in Remarks Column .................. 60

Suggested Spare Parts ............................................. 61

MQPower DCA 85SSJUMQPower DCA 85SSJU

MQPower DCA 85SSJU

MQPower DCA 85SSJUMQPower DCA 85SSJU
AC GeneratorAC Generator

AC Generator

AC GeneratorAC Generator

Generator Assembly ............................................. 62-63

Control Box Assembly ........................................... 64-67

Engine & Radiator Assembly................................. 68-71

Engine Operating Panel Assembly ........................ 72-73

Output Terminal Assembly ..................................... 74-75

Battery Assembly .................................................. 76-77

Muffler Assembly .................................................. 78-79

Fuel Tank Assembly ............................................ 80-81

Enclosure Assembly ............................................. 82-85

Rubber Seal Assembly .......................................... 86-87

Name Plate And Decals ........................................ 88-89

Terms and Condition of Sale — Parts ....................... 90

NOTE

Specification and part number
are subject to change without
notice.

PAGE 4 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

PARTS ORDERING PROCEDURES

For faxed orders only

UPS

Special

■■

■ Dealer account number

■■

■■

■ Dealer name and address

■■

■■

■ Shipping address (if different than billing address)

■■

■■

■ Return fax number

■■

■■

■ Applicable model number

■■

■■

■ Quantity, part number and description of each part

■■

■■

■ Specify preferred method of shipment:

■■

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:

Number of
line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Get special freight allowances
when you order 10 or more
line items via FAX!**

■■

■

UPS Ground Service at no charge for freight

■■

■■

■

PS Third Day Service at one-half of actual freight cost

■■

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.

Extra Fax DiscountExtra Fax Discount

Extra Fax Discount

Extra Fax DiscountExtra Fax Discount

for Domestic USAfor Domestic USA

for Domestic USA

for Domestic USAfor Domestic USA

Dealers OnlyDealers Only

Dealers Only

Dealers OnlyDealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Failure to follow instructions in this manual
may lead to serious injury or even death!
This equipment is to be operated by trained

and qualified personnel only! This equipment
is for industrial use only.

RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.

The following safety guidelines should always be used when
operating the DCA-85SSJU portable generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before
reading this entire manual.

■

This equipment should not be operated by
persons under 18 years of age.

■

NEVER operate this equipment without proper
protective clothing, shatterproof glasses,
steel-toed boots and other protective devices
required by the job.

■

NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the
influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any
accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts
before starting.

■

High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with
burns.

■

The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people. The generator engine gives off DEADLY carbon
monoxide gas.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

explosive atmosphere or near combustible materials. An
explosion or fire could result causing severe

or even death.

Topping-off to filler port is dangerous, as it tends to spill
fuel.

hot

components can cause serious

:

Always refuel in a well-ventilated area,
away from sparks and open flames.

■

Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT smoke around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.

NEVER operate the generator in an

bodily harm

PAGE 6 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

RULES FOR SAFE OPERATION

:

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

DO NOT touch or open any of the below

mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.

NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

■

Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

:

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.

while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.

plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.

Never use damaged or worn cables when
connecting power tools or equipment to the

generator. Make sure power connecting
cables are securely connected to the

generator’s output terminals, insufficient
tightening of the terminal connections may

cause damage to the generator and
electrical shock.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 7

RULES FOR SAFE OPERATION

Battery

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.

2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.

:

Never over fill the battery with water
above the upper limit.

NEVER Run engine without air filter. Severe engine
damage may occur.

Always service air cleaner frequently to prevent carburetor
malfunction.

Always disconnect the battery before performing service
on the generator.

Always be sure the operator is familiar with proper safety
precaution s and operations techniques before using
generator.

Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.

DO NOT leave the generator running in the manual mode
unattended.

DO NOT allow unauthorized people to operate this
equipment.

Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.

Refer to the
engine technical questions or information.

Loading and Unloading (Crane)

John Deere Engine Owner's Manual

for

3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.

6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.

clothing or skin

, rinse skin or clothing

Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.

Always drain fuel prior to lifting.
Always make sure crane or lifting device has been

properly secured to the hook of guard frame on generator.

NEVER lift the machine while the engine is running.

Use adequate lifting cable (wire or rope) of sufficient
strength.

When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.

NEVER allow any person or animal to stand underneath
the machine while lifting.

When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.

PAGE 8 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

Transporting

Always shutdown engine before transporting.
Tighten fuel tank cap securely.
Drain fuel when transporting generator over long distances

or bad roads.
Always tie-down the generator during transportation by

securing the generator.
If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.

Emergencies

RULES FOR SAFE OPERATION

Always know the location of the nearest
and

first aid kit

Also know the phone numbers of the nearest

doctor

Maintenance Safety

and

NEVER lubricate components or attempt service on a
running machine.

Always allow the machine a proper amount of time to
cool before servicing.

Keep the machinery in proper running condition.
Fix damage to the machine immediately and always

replace broken parts.
Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.

DO NOT use plastic containers to dispose of hazardous
waste.

DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.

. Know the location of the nearest telephone.

fire department

.

fire extinguisher

ambulance

,

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 9

DCA-85SSJU — TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

Check with your county or state safety
towing regulations department before towing
your generator.

To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 1) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.

The following list of suggestions should be used when towing
your generator:

Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).

ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.

Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.

ALWAYS make sure the trailer is equipped with a "Safety
Chain".

ALWAYS attach trailer’s safety chain to bumper of towing

vehicle.
ALWAYS make sure the vehicle and trailer directional,

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

The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.

Place
rolling, while parked.

Place
prevent tipping, while parked.

Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.

Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve gas milage.

Avoid sharp turns to prevent rolling.
.Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 1. Generator with Trailer

PAGE 10 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — TRAILER-SAFETY GUIDELINES

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.

Explanation of Chart:

This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply to a wide range of
trailers. Periodic inspection of the trailer will ensure safe
towing of the equipment and will prevent damage to the equip­ment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans­porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, in­cluding the fuel cell (empty).

4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to
fender.

6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.

13. Axle - Indicates the maximum weight the axle can sup­port in pounds, and the diameter of the axle expressed
in inches (see Table 3). 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.

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.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 11

DCA-85SSJU —TRAILER-SPECIFICATIONS

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

DCA-85SSJU —TRAILER-SPECIFICATIONS

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DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 13

DCA-85SSJU —TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:



Brake system can be manually adjusted to provide

the corrected braking capability for varying road and
load conditions



Brake system can be modulated to provide more or

less braking force, thus easing the brake load on the
towing vehicle



Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the trailer’s brakes
are actuated



Brake system can provide an independent emergency

brake system

Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only be accomplished
by road testing. Brake lockup, grabbiness or harshness is
due to lack of synchronization between the tow vehicle
and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be
made, the trailer brakes should be burnished-in by applying
the brakes 20-30 times with approximately a 20 m.p.h.
decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.

Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.

5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.

6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer
to the ground.

8. Repeat steps 1 through 6 on the remaining brakes.

PAGE 14 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such
as shoe and lining replacement. These brakes can be
adjusted in the same manner as electric brakes. Brake
lines should be periodically checked for cracks, kinks, or
blockage.

Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the electric brake adjustments
section.

Figure 3. Hydraulic Brake Components

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 15

DCA-85SSJU — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.

CAUTION:

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

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

Suspension

The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.

PAGE 16 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

Figure 4. Major Suspension Components

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DCA-85SSJU —TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.

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

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DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 17

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Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-85SSJU —TRAILER-WIRING DIAGRAM

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU —TRAILER-BRAKE TROUBLESHOOTING

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DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 19

DCA-85SSJU —TRAILER-BRAKE TROUBLESHOOTING

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PAGE 20 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — GENERATOR DECALS

The DCA -85SSJU generator is equipped with a number of safety decals. These decals are provided for operator safety
and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

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

DCA-85SSJU — GENERATOR DECALS

PAGE 22 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — SPECIFICATIONS

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DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 23

seiD2#

DCA-85SSJU — GENERAL INFORMATION

DCA-85SSJU FAMILIARIZATION

Generator

The MQ Power Model DCA-85SSJU is a 68 kW
that is designed as a high quality portable (requires a trailer
for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.

Engine Control Panel

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



Tachometer



Water Temperature Gauge



Oil Pressure Gauge



Charging Ammeter Gauge



Engine Speed Switch



Microprocessor Engine Controller (engine controller)



Pre-Heat Button



Panel Light



Panel Light Switch

Generator Control Panel

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



Output Voltage Adjustment Knob



Frequency Meter (Hz)



AC Ammeter (Amps)



AC Voltmeter (Volts)



Ammeter Change-Over Switch



Voltmeter Change-Over Switch

generator

Open Delta Excitation System

The DCA-85SSJU generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the
power to the
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.

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

The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load.

Microprocessor Controlled Alarm System

The DCA-85SSJU generator is equipped with various alarms
and LED status indicators. These alarms and status
indicators are provided to add safety to the generator when
operating under normal conditions. The DCA-85SSJU
generator is designed to shutdown in the event of low oil,
high coolant temperature, low battery and other operation
conditions that may cause severe damage to the engine.

Engine

Open-Delta

" excitation system. The open delta

Automatic Voltage Regulator

fixed ceiling

(AVR) is supplied

" and responds

Output Terminal Panel

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



Three 240/139V output receptacles, 50 amp



Two 120V input receptacles, 20 amp



3 Load Circuit Breakers 265V @65 amps



2 Load GFCI Circuit Breakers 265V@ 20amps

Control Box

The “Control Box” is provided with the following:



Main Circuit Breaker 250 amps



Over-Current Relay

PAGE 24 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

The DCA-85SSJU is powered by a 4 cycle, water cooled,
turbocharged JOHN DEERE Model 4045TF 250
engine. This engine is designed to meet every performance
requirement for the generator. Reference Table 7, page 23
for engine specifications.

In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.

The basic controls and indicators for the DCA-85SSJU
generator are addressed on the following pages.

diesel

DCA-85SSJU — MAJOR COMPONENTS

Figure 6. Major Components

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 25

DCA-85SSJU — DIMENSIONS

Figure 7. Dimensions

PAGE 26 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

NOTE PAGE

Figure 3b. Dimensions

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 27

DCA-85SSJU — CONTROL PANEL

Figure 8. Control Panel

PAGE 28 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — CONTROL PANEL

The definitions below describe the controls and functions of
the DCA-85SSJU "

1. Main Circuit Breaker – This three-pole, 250 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.

2. AC Ammeter – Indicates the amount of current the
load is drawing from the generator.

3. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.

4. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.

5. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.

Control Panel

" (Figure 8).

6. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the single phase output
voltage present at the UVW terminals.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 29

DCA-85SSJU — ENGINE OPERATING PANEL

Figure 9. Engine Operating Panel

PAGE 30 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of
the DCA-85SSJU "

1. Panel light - Normally used in dark places or at night.
When activated, panel will luminate. When the generator
is not in use, 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 – Normal operation should be about
42~71 psi. When starting the generator the oil pressure
may read a bit higher, but after the engine warms up
the oil pressure should return to normal.

4. Water Temperature Gauge – During normal operation
this gauge be should read between 165oF to 203oF.

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. Engine Speed Switch- This handle will change the
speed of the engine from high to low.

9. Pre-Heat Button – Press hold this button
until the preheat lamp is lit (ON).

Engine Operating Panel

" (Figure 10).

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 engine
controller will shutdown the engine by initializing the "Over
Speed Protection" mode.
Also the engine controller will shutdown the generator 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 engine controller module.

A. Off/Manual/Auto Switch – This switch controls the

running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the
immediately.

If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place the
switch in the
will monitor the AC line output from the building's power
source.

B. Low Oil Pressure – Indicates the engine pressure

has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered a

major

fault.

manual

position, the generator will start

auto

position. In this position the generator

major

fault.

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times,

10. Auto/Stop Manual Engine Controller- Has a vertical

row of status LED's (Figure 11), that when lit, indicate that
an engine malfunction (fault), has
been detected. When a fault has
been detected the engine controller
will evaluate the fault and all major
faults will shutdown the generator.
During
controller will attempt to crank the
engine for 10 seconds before

cranking cycle

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 31

, The

Figure 11. Engine

Controller

and has failed to start. The number of cycles and duration
are programmable. It is preset at 3 cycles with a 10
second duration. This is considered a

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

F. Engine Running – Indicates that engine is running at

a safe operating speed.

major

major

fault.

fault.

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

OUTPUT TERMINAL FAMILIARIZATION

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



Three 120/240V output receptacles, 50 amp



Two 120V receptacles, 20 amp



3 Circuit Breakers 240V @50 amps



2 GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:



Main Circuit Breaker 250 amps



Over-Current Relay

Output Terminal Panel

The Output Control Panel (See Figure 14) is located on the
right hand side (left from control panel) of the generator.
The UVW lugs are protected by a face plate cover that can
be secured in the close position by a pad lock. (See Figure

11).

Connecting Load

Loads can be connected to the generator by the UVW Lugs or
the convienience receptacles. (See Figure 13). Make sure to
read the operation manual before attempting to connect a load
to the generator.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 240 amp,

main

circuit breaker is provided to protect the UVW 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
have also been provided to protect the load side of the
generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

FIGURE 13. Connecting Load

load

circuit breakers

ALL

circuit

FIGURE 11. Output Terminal Cover

120 Volt Recetacle

Two GFCI Duplex Nema 5-20R (120V, 20 Amp) recepacle is
provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.

Pressing the reset button resets the receptacle after being
tripped. Pressing the "Test Button" (See Figure 12) in the
center of this receptacle will check the GFCI function. The
receptacle should be tested at least once a month.

FIGURE 12. GFCI Test Button

PAGE 32 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

Maximum Output

The entire load connected to the UVW Lugs, all four slots in the
duplex receptacles, and the must not exceed 70 kW in standby
or 65 kW in prime output.

Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
Control Panel. Place the voltmeter change-over switch to
the U-W positon and the ammeter change-over switch to
the U or W to read the output.

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

FIGURE 14. Output Terminal Panel

NOTE

Legs O and Ground are
considered Bonded Grounds.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 33

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

Output Terminal Panel Available Voltages

A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and how you hookup

Maximum Amps

The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed. (See Table 9 below.)

your hard wire connection to the generator. To obtain some
of the voltages listed, fine adjustment with the Voltage
Regulator on the control panel is necessarry. See the
table below (Table 8) for a list of available voltages the
generator is able to supply.

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Voltage Selector Switch

The voltage selector switch is located above the UVWO
Hard Wire Hook-up Panel. It has been provided for ease of
voltage selection.

CAUTION :

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Receptacle Use

When the UVWO terminals are providing power, the
receptacle power available decrease. Do not exceed
receptacle power available listed on Table 10.

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Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the Voltage Selector Switch,
press in the red button located on the Voltage Selector
Switch, and use a pad lock to hold it into this position.
(See figure 17, page 37)

Over Current Relay

An over current relay is connected to the circuit breaker.
In an over current situation, 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.

PAGE 34 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

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DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

How to read the output terminal gauge.

The gauge and knobs on the control panel DO NOT effect
the generator output . They are to help observe how
much power is being supplied produced at the UVWO
legs.

When the Voltage selector switch is in the 240/120V
position (see Figure 15), place the AC Voltmeter Change­over switch to the W-U position and the AC ammeter
Change -over Switch to the U or W position to read the
output on the selected leg.

FIGURE 18. AC Ammeter

(Reading the U leg on the

Change-over Switch

output terminal panel)

NOTE

When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.

40

20

0

60

75

A

FIGURE 19. AC Ammeter

(Amp reading on U lug)

FIGURE 15. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 16. AC Voltmeter

Change-over switch

(Reading the W-U leg on

the outputerminal panel)

FIGURE 17. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 35

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

240/120V Hard Wire Hookup

The output terminal panel, when suppling single phase 120
volts, will provide three legs available with 183 amps each
on three different circuits. (See Figure 21 below.) The voltage
selector switch must be set at the single phase 240/120V
position. (See figure 20 below.)

The output terminal panel, when suppling single phase 240
volts, will provide one leg only with 91.6 amps available.
(See Figure 23) when the voltage selector switch is at the
single phase 240/120V position.

480/240V Hard Wire Hookup

The output terminal panel, when suppling three phase 240
volts, will provide one circuit available at 198 amps with any
two wires plus the ground. (See Figure 23 below.) The voltage
selector switch must be set at the three phase 480/277V
position. (See figure 22 below.)

The output terminal panel, when suppling 3 phase 480 volts,
will provide one circuit available at 99 amps available with
all three wires plus ground. (See Figure 23) when the voltage
selector switch is set at the three phase 480/277V position.

FIGURE 20. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 21. Hard Wire Hook-up at 240/120V Position

FIGURE 22. Voltage Selector Switch 480/277V Three Phase

Position

FIGURE 23. Hard Wire Hook-up at 480/240V Position

PAGE 36 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

Voltage Selector Switch- 3 Phase 480/277V Position

The following are additional voltages available when the
voltage selector switch is in the 3 phase 480/277V
position. (See figure 24 below.)

Single Phase: 480V, 440V, or 416 Volt

The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 24),
can offer SINGLE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
figure 27 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 25).

FIGURE 25. Voltage

Selector Switch 270/120V

Single Phase Position

FIGURE 24. Voltage Selector Switch 480/277V Single Phase

Position

FIGURE 27. Hard Wire Hook-up for Single Phase 480V, 440V,

or 416V

Single Phase: 277V, 254V, or 240V

3 Phase, 480V, 440V, or 416 Volt

The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 24),
can offer THREE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
figure 28 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward

The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 28),
can offer SINGLE PHASE power at 277V, 254V, or 240V.
After hooking up the hard wires to the lugs as shown in
figure 28 below, 277V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 254 volt will be
reached when the Voltage Regulator Knob is turned down,
and 240 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 25).

the lowest setting (See Figure 25).

FIGURE 26. Hard Wire Hook-up for Three Phase 480V, 440V,

or 416V

FIGURE 28. Hard Wire Hook-up for Single Phase 277V, 254V,

or 240V

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 37

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the
voltage selector switch is in the 3 phase 240/139V
position. (See Figure 29 below.)

Single Phase: 240V, 220V, or 208 Volt

The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer SINGLE PHASE power at 240V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
figure 32 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).

FIGURE 30. Voltage

Regulator Knob located

on the control panel

FIGURE 29. Voltage Selector Switch 240/139V Three Phase

Position

FIGURE 32. Hard Wire Hook-up for Single Phase 240V, 220V,

or 208V

3 Phase, 240V, 220V, or 208 Volt

The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer THREE PHASE power at 270V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
figure 31 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).

FIGURE 31. Hard Wire Hook-up for Three Phase 240V, 220V,

or 208V

Single Phase: 139V, 127V, or 120V

The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 29),
can offer SINGLE PHASE power at 139V, 127V, or 120V.
After hooking up the hard wires to the lugs as shown in
figure 33 below, 139V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 127 volt will be
reached when the Voltage Regulator Knob is turned down,
and 120 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 30).

FIGURE 33. Hard Wire Hook-up for Single Phase 139V, 127V,

or 120V

PAGE 38 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — OUTPUT TERMINAL PANEL OVERVIEW

Voltage Selector Switch- Single Phase 240/120V
Position

The following are additional voltages available when the
voltage selector switch is in the single phase 240/120V
position. (See Figure 34 below)

Single Phase: 120 Volt

The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 34), will offer SINGLE PHASE power at 120V. After
hooking up the hard wires to the lugs as shown in figure 37
below, use the Voltage Regulator Knob to fine tune to
120V. (See Figure 35).

FIGURE 35. Voltage

Regulator Knob located

on the control panel

FIGURE 34. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 37. Hard Wire Hook-up for Single Phase, 120 volt

Single Phase, 240 Volt

The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 34), will offer SINGLE PHASE power at 240V. After
hooking up the hard wires to the lugs as shown in figure 36
below, use the Voltage Regulator Knob to fine tune to
240V. (See Figure 35)

FIGURE 36. Hard Wire Hook-up for Single Phase 240 volt

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 39

DCA-85SSJU — INSTALLATION

Outdoor Installation

Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so that it cannot slide or shift around. Also
install the generator in a manner so that the exhaust will not
be discharged in the 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 CAUTION

CAUTION

CAUTION CAUTION

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.

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.

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 - 10 AWG (5.3 mm2) or larger.

:

An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

Indoor Installation

Exhaust gases from diesel engines are extremely 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.

2. When grounding the generator (Figure 38) 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.

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

NOTE

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

PAGE 40 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — INSTALLATION

Figure 38. Typical Generator Grounding Application

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 41

DCA-85SSJU — PRE-SETUP

General Inspection Prior to Operation

The DCA-600SSK generator has been thoroughly
inspected and accepted prior to shipment from the factory.
However, be sure to check for damaged parts or
components, or loose nuts and bolts, which could have
occurred in transit.

Extension Cable

When using extension cords or cables, the distance,
length, and cable size should be considered when
using them to power various loads. 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. This is
determined from its load current, length and thickness
according to the following this equation for three­phase, three-line system:

e=1/58 x L/S x I x 1.723
e=voltage drop (V), L=cable length (m), S=cable

thickness (mm2), and I=load current (A). Be sure to
select the cable length and thickness that will not
exceed the voltage drop by 5%.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 250 amp,

main

terminals from overload. In addition two single-pole, 20 amp

GFCI

receptacles from overload. Three 50 amp
have also been provided to protect the load side of the
generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

circuit breaker is provided to protect the UVW output

circuit breakers are provided to protect the GFCI

load

circuit breakers

ALL

circuit

NOTE

ALWAYS consult with a licensed

electrician for correct extension
cord wire size.

PAGE 42 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — PRE-SETUP

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

Fuel

Fill the fuel tank with clean and fresh
fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23,
Specification Table 7.

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Coolant

diesel fuel.

DO NOT

:

Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on a
hot engine can cause a fire or explosion.
If diesel spillage occurs, wipe up the spilled
diesel completely to prevent fire hazards.

Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.

Figure 39. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is
clean and viscous. 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 John Deere Engine Owner's

Manual.

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An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.

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DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 43

3-W0EAS

DCA-85SSJU — PRE-SETUP

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve 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 reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.

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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
battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere 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 John

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 7 to 10
mm (Figure 40) when depressed with the thumb as shown
below.

Operation in Freezing Weather

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

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NOTE

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

1622

Figure 40. Fan Belt Tension

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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 is not
properly maintained. Add only distilled water when
replenishment is necessary.
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 the battery is
discharged and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help inhibit corrosion.

:

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

PAGE 44 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — PRE-SETUP

Battery Cable Installation
ALWAYS be sure the battery cables (Figure 41) 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.

Figure 41. Battery Connections

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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.

:

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

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery

terminals when the
the manual or auto position (ON). ALWAYS make sure
that the Off/Manual/Auto switch is in the OFF position
when connecting the battery.

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.

Off/Manual/Auto

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 45

switch is in either

DCA-85SSJU — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency 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.

NOTE

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 14
below when connecting loads.

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CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

which cannot carry the required load can cause a voltage
drop which can burn out the appliance or tool and overheat
the cable.



When connecting 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.

CAUTION:

:

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

An inadequate size connecting cable

Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.

Three Phase Load

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

PAGE 46 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

NOTE

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

DCA-85SSJU — GENERATOR START-UP PROCEDURE

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 7 on page 37).

3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure that the radiator cap is
fastened securely.

ALWAYS

ventilate the

2. Connect the load to the UVW terminals as shown in
Figure 44. These terminals can be found on the output
terminal panel, (see page 32 Figure 14 for description
and usage of receptacles). To gain access to the output
terminals lift the UVW cover. Tighten terminal nuts
securely to prevent load wires from slipping out.

Figure 44. UVW Terminal Lugs (Load)

4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.

Before Starting

Generator and Control Panel

3. Connect the negative battery cable (BLACK) to the

CAUTION:

NEVER start the engine with the

main, GFCI

in the ON position.

1. Be sure to disconnect the
electrical load and switch the
circuit breakers (Figure 43) to the “OFF” position prior to
starting the engine.

or

load

circuit breakers

main, load

and

G.F.C.I.

negative post on the battery (Figure 45).

NEGATIVE

POSTIVE

BATTERY

Figure 45. Battery Connections

Figure 43. Main, GFCI and

Load Circuit Breakers

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 47

DCA-85SSJU — GENERATOR START-UP PROCEDURE

4. Close all engine enclosure doors (Figure 46).

Figure 46. Engine Enclosure Doors

5. When starting the generator in COLD weather conditions,
press and hold the engine preheat button (Figure 47) .

Figure 47. Engine Pre-Heat Button

8. Turn the Auto-Off/Reset-Manual switch to ‘Manual’ to
start the engine (Figure 50). Once the engine
starts, let the engine run for 1-2 minutes. Listen for
any abnormal noises.

Figure 50. Auto-Off/Reset-Manual Switch

9. Once the engine is warm and the engine is running
properly, set the engine speed switch to ‘High’
(Figure 51).

6. Check the voltage selection switch is at the desired
voltage (Figure 48).

10. The generator's frequency meter (Figure 52)displays the
60 cycle output frequency in HERTZ.

Figure 48. Voltage Selection Switch

7. Set engine speed switch to ‘Low’ (Figure 49).

Figure 49. Engine Speed Switch (low)

11. The generator's voltage meter (Figure 53) displays the

Figure 51. Engine Speed Switch (high)

Figure 52. Frequency Meter (Hz)

120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 54) to increase or
decrease the desired voltage.

Figure 53. Voltmeter

PAGE 48 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — GENERATOR START-UP PROCEDURE

Figure 54. Voltage Adjust Control Knob

15. The tachometer (Figure 58) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed is approximately 1800
RPM’s.

12. The ammeter (Figure 55) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.

40

20

0

60

75

16. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 59).

A

Figure 55. Ammeter (No Load)

13. The engine oil pressure gauge (Figure 56) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
25 psi.

Figure 56. Oil Pressure Gauge

Figure 59. Main and GFCI Circuit Breakers

17. Observe the generator's ammeter (Figure 60) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if the load is in use.

Figure 58. Engine Tachometer

40

20

0

60

75

14. The coolant temperature gauge (Figure 57) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature is between 165 and
215 degrees Fahrenheit.

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

WATER TEMP

Figure 57. Coolant Temperature Gauge

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 49

A

Figure 60. Ammeter (Load)

DCA-85SSJU — GENERATOR START-UP PROCEDURE (AUTO)

CAUTION:

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

injury

or

death

CAUTION:

When connecting the generator to a
isolation (transfer) switch, ALWAYS have
power applied to the generator's internal
battery charger. This will ensure that the
engine will not fail due to a dead battery.

Starting the generator in the "AUTO" mode is similar to
starting the generator in the "MANUAL" mode, with a few
exceptions.

CAUTION:

When running the generator in the AUTO
mode, remember the generator can start
up at any time without warning. NEVER
attempt to perform any maintenance
when the generator is in the auto mode.

When starting generator in Auto mode use the "Manual Start­up" procedure except where noted (see below).

1. Perform steps 1 through 10 (Before Starting, page 47-

48) as outlined in the manual starting procedure.

2. Place the Off/Manual/Auto switch (Figure 61) in the

AUTO position .

Figure 61. Off/Manual Auto Switch (AUTO)

3. Continue to follow the steps outline in the manual start­up procedure (start at step 12, page 50).

PAGE 50 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU— GENERATOR SHUT DOWN PROCEDURE

ENGINE SHUTDOWN

To shutdown the generator, use the following procedure:

1. Switch both the MAIN, GFCI and LOAD circuit breakers
(Figure 62) to the “OFF” position.

Figure 62. Main, GFCI and Load

circuit breakers

2. Set the engine speed switch (Figure 63) to the idle
(low) position.

Figure 63. Engine Speed Switch

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

4. Turn the Auto-Off/Reset-Manual switch from the engine

controller to “OFF/Reset” position (Figure 64).

Figure 64. Off/Manual Auto Switch

5. Remove the load from the UVW terminal strip.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 51

DCA-85SSJU — MAINTENANCE

General Inspection

Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel
or oil leaks.

Engine Side, Fuel, Oil and Coolant (Refer to the Engine

Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy
duty paper element with kerosene, or foam element with
liquid detergent and hot water. Wrap foam element in a cloth
and squeeze dry. For heavy duty paper element, wipe
excess kerosene with towel.

Fuel Addition

Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.

Removing Water from the Tank

After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water
to condense. This can be reduced by always keeping the
tank as full as possible.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.

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 page 39, Figure 13.

Generator Storage

For storage of the generator for over 30 days, the following
is required:



Drain the fuel tank completely.



Completely drain the oil from the crankcase and refill
with fresh oil.



Clean all external parts of the generator with a cloth.



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

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.

To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.

PAGE 52 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — MAINTENANCE

51elbaT-ecnanetniaM

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

1

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

leveL

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

2

*retliFleuFegnahC

noitcetorPtnalooCkcehCdnarotaidaRnaelC

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

srH01

YLIAD

srH052 srH005 srH0001

X

X

X

knaTleuFfoedisnInaelC X

ROTARENEG

1

*

2

*

smhoM3revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

X

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 53

DCA-85SSJU — GENERATOR WIRING DIAGRAM

PAGE 54 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENGINE WIRING DIAGRAM

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 55

DCA-85SSJU — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

?tungniniaterepip

diagnosis based on the Engine Troubleshooting (Table 16). If
the problem cannot be remedied, consult our company's
business office or service plant.

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero

noitcejniesooloteudkaelleuF

.tunnethgiT

GNITOOHSELBUORTENIGNE.61ELBAT

.lioenigneroleufdeificepsehtesU

.tratstonseodenignE

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?rednilycmorfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?gninoitcnuflamretratS .ecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

PAGE 56 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

tsuahxeyargkradrokcalbrehtiE

.devresbosisag

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

.ecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?gnizieseb

.tuptuotneicifeD

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?kaelnoisserpmoC

otmeesstrapgnivoms'enignE

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 57

DCA-85SSJU — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for

diagnosis based on the Generator Troubleshooting (Table17)
or Engine Controller Troubleshooting (Table 18). If the problem
cannot be remedied, consult our company's business office
or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

GNITOOHSELBUORTROTARENEG.71ELBAT

?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

deppirTrekaerBtiucriC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 58 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — TROUBLESHOOTING (ENGINE CONTROLLER)

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

GNITOOHSELBUORTRELLORTNOCENIGNE.81ELBAT

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

L

.nosi

tnaloochgiH

thgilleveltnaloocwo

.nosithgilerutrepmet

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL .yrettab

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytlua

?eruliaftatsomrehT.tatsomrehtecalpeR

?

dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplio

?rellortnocninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

hguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

?rotaidar

ecalpeR

egrahc/ecalpeR

frosteksagriaper/ecalpeR

?leuFwolrooN.levelleuflliF

vO

PMfossoL

.nosithgilknarcre

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

?hgiho

otdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

.nosithgildeepsrevO

ellortnocronrevoG .rellortnocronrevogtsujdA

citengam(U

.noro)s(thgil)pukcip

?ytridUPM.UPMnaelC

?tnemtsujdafotuoUPM.UPMtsujdA

?detsujdaebotsdeenr

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 59

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts
book.

Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial

number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the

corresponding part is utilized only with this specific model
number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #,
+, or % belong to the same assembly or kit.

Note: If more than one of the same reference number is
listed, the last one listed indicates newest (or latest)
part available.

PAGE 60 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — SUGGESTED SPARE PARTS

DCA-85SSJU W/JOHN DEERE DIESEL ENGINE

1 to 5 Units

Qty. P/N Description

10 .............. 6125817032 ..................... AIR FILTER

10 .............. 6003118293 ..................... FUEL FILTER

10 .............. 6002111231 ..................... OIL FILTER

5 ................ 6004111151 ..................... CARTRIDGE, CORROSION RESISTOR

1 ................ 0601840487 ..................... CIRCUIT BREAKER

2 ................ 0412121757 ..................... ENGINE FAN BELT

1 ................ 6008155390 ..................... SWITCH, STARTER

5 ................ 615 ................................... KEY SET, STARTER SWITCH (2)

2 ................ 0602122281 ..................... OIL SWITCH

1 ................ 6152611520 ..................... RADIATOR HOSE (UPPER)

1 ................ 6152611531 ..................... RADIATOR HOSE (LOWER)

1 ................ 0802010900 ..................... FUEL CAP

1 ................ 061820625 .......................AUTOMATIC VOLTAGE REGULATOR

1 ................ 0601807373 ..................... MAIN CIRCUIT BREAKER

1 ................ 0601805840 ..................... CIRCUIT BREAKER

1 ................ 0601810072 ..................... PILOT LAMP

2 ................ 0601810261 ..................... BULB, PILOT LAMP

1 ................ 23S0311150M ..................CAP, RADIATOR

1 ................ 0602122200 ..................... UNIT, OIL PRESSURE

1 ................ 0602123206 ..................... UNIT, WATER TEMPERATURE

1 ................ 0602121052 ..................... CHARGING AMMETER

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 61

GENERATOR ASSY.

GENERATOR ASSY.

DCA-85SSJU — GENERATOR ASSY.

PAGE 62 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B6110000102 ROTOR ASS’Y 1
2 FIELD ASS’Y 1
3 8101070033 FAN 1
4 8101611004 COUPLING DISK 5
5 8101015003 BALANCING PLATE 1

6 012010030 HEX. HEAD BOLT .............................. 8 ...........REPLACES 0012110030

7 0042510000 LOCK WASHER 8

8 030210250 SET PLATE, RECTIFIER ................... 1 ...........REPLACES 8101026013

9 0601821349 RECTIFIER ........................................2 ...........PT 3610

10 0601822601 SURGE ABSORBER .......................... 1 ...........ERZ- M14JK621A

11 8001020004 INSULATOR WASHER 1
12 8001020504 INSULATOR WASHER 1
13 0010110020 HEX. HEAD BOLT 4
14 0040010000 LOCK WASHER 4
15 0601000209 BALANCING WEIGHT KIT 1

16 0071906311 BEARING ........................................... 1 ...........6311 DDU C3

17 B6130000203 STATOR ASS’Y 1
18 0845041804 GROMMET 2
19 8101315202 END BRACKET 1
20 8101350013 FIELD ASS’Y, EXCITER 1
21 0012110070 HEX. HEAD BOLT 4
22 0042610000 LOCK WASHER 4

23 031110160 PLAIN WASHER .................................4 ........... REPLACES 0041210000

24 0010110035 HEX. HEAD BOLT 6
25 0040010000 LOCK WASHER 6

26 031110160 PLAIN WASHER .................................6 ........... REPLACES 0041210000

27 8101310014 COVER, BEARING 1
28 8131312014 GASKET, BEARING 1
29 8101331003 COVER, END BRACKET 1

30 0105050616 HEX. HEAD BOLT ............................ 10 ..........REPLACES 0017106012

31 8101333003 COVER, END BRACKET 1
32 0010106030 HEX. HEAD BOLT 2
33 0040006000 LOCK WASHER 2

34 952404470 PLAIN WASHER ................................. 2 .......... REPLACES 0041206000

35 8101614003A COUPLING RING ............................... 1 .......... REPLACES M2163400003

36 0343204170 HEX. HEAD BOLT 8

37 EM923344 LOCK WASHER .................................. 8 ..........REPLACES 0043604000

38 0070506306 BEARING ........................................... 1 .......... 6306ZZ

39 0012810035 HEX. HEAD BOLT 8
40 0012810030
41 8111332014 COVER, FAN 1

42 020106050 NUT .................................................... 1 ..........REPLACES 0600815000

43 0605000010 RUBBER SUSPENSION 2
44 0030012000 HEX. NUT 2

0040012000 LOCK WASHER 2

031112230 PLAIN WASHER ................................. 2 ..........REPLACES 0041212000

HEX. HEAD BOLT 12

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 63

CONTROL BOX ASSY.

DCA-85SSJU — CONTROL BOX ASSY.

PAGE 64 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

M2248700104 WIRE HARNESS, GENERATOR 1
1 M2215000002 CONTROL BOX 1

2 0601808814 CIRCUIT BREAKER ....................................1 .......... KAF362501021 3P 250A

3 0021005080 MACHINE SCREW 4

4 0601823863 RELAY UNIT ............................................... 2 .......... MSA9013A

5 0021304015 MACHINE SCREW ......................................4 .......... REPLACES 0027104015

6 0601820671 AUTOMATIC VOLTAGE REGULATOR.......... 1 .......... NTA5A2DB

7 0027105015 MACHINE SCREW 4

8 0601806118 CURRENT TRANSFORMER ....................... 3 ..........814943 200 /5A

9 011808015 MACHINE SCREW ......................................6 .......... REPLACES 0027106015

10 0601820846 OVER CURRENT RELAY ............................1 .......... LA7D1064

11 0601820845 OVER CURRENT RELAY ............................1 .......... LR2D1308

12 0021304015 MACHINE SCREW ......................................2 .......... REPLACES 0027104015

0030004000 HEX. NUT ....................................................2 .......... REPLACES 0207004000

13 LY2US12VD RELAY ......................................................... 1 .......... REPLACES 0601823768

PTF08AE BASE .......................................................... 1 .......... REPLACES 0601823109

PYCA1 CLIP ............................................................ 2 ..........REPLACES 0601824400

14 0027104020 MACHINE SCREW 2
15 M2213500103 CONTROL BOX COVER 1

16 011106015 HEX. HEAD BOLT .......................................4 .......... REPLACES 0016906015

17 M3923100004 SELECTOR SWITCH .................................. 1 .......... VY 125

18 M2215600003 SWITCH BRACKET 1

19 EDGEGES EDGING ...................................................... 2 .......... REPLACES 0330000295

20 0027103010 MACHINE SCREW 4

21 011106015 HEX. HEAD BOLT .......................................6 .......... REPLACES 0016906015

22 M2215600104 SWITCH COVER 1

23 011106015 HEX. HEAD BOLT .......................................4 .......... REPLACES 0016906015

24 011106015 HEX. HEAD BOLT .......................................8 .......... REPLACES 0016906015

0040506000 TOOTHED WASHER 1
25 M2223000103 CONTROL PANEL 1

26 0601807630 FREQUENCY METER ................................ 1 .......... UP TO S/N7700090;

264250DJDJ9

0601807641 FREQUENCY METER ................................ 1 ..........S/N7700091~;

FCF645~65Hz 240V

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 65

CONTROL BOX ASSY.

CONTROL BOX ASSY.

DCA-85SSJU — CONTROL BOX ASSY.

PAGE 66 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

27 0601808953 AC AMMETER ............................................ 1 .......... UP TO S/N7700090;

260240LSLS1JCA

0601808988 AC AMMETER ............................................ 1 .......... S/N7700091~;

ACF6 0-800A, 0-400A/5A

28 0601801040 CHANGE- OVER SWITCH, AMMETER ..... 1 .......... SL- 2AS

29 0601806813 AC VOLTMETER ......................................... 1.......... UP TO S/N7700090;260244SJSJ1

0601806859 AC VOLTMETER ......................................... 1 .......... S/N7700091~; SCF6 0-600V

30 0601801041 CHANGE- OVER SWITCH, VOLTMETER ... 1.......... SL- 2VS

31 0601840073 RHEOSTAT ( VOLTAGE REGULATOR ) .......1 ..........RA20A2SE102BJ 2W 1K OHM

32 0601840121 KNOB 1
33 M1223100004 STOPPER 1
34 0027105010 MACHINE SCREW 2
35 0027105010 MACHINE SCREW 4
36 M9220100004 SET SCREW 1
37 0080200007 SNAP RING 1

38 DYN110794000012 CONTROLLER ............................................ 1 .......... REPLACES 0602202599

39 0027105015 MACHINE SCREW 4

40 0602120485 SPEED SENSOR ....................................... 1 .......... MPS6724

41 0602202592 STARTER RELAY ........................................ 1 .......... AT141011

42 011808015 MACHINE SCREW ......................................2 .......... REPLACES 0027106015

43 LY2DDC12V RELAY .........................................................1 .......... REPLACES 0601827656

PTF08AE BASE .......................................................... 1 .......... REPLACES 0601823109

PYCA1 CLIP ............................................................ 2 ..........REPLACES 0601824400

44 0027104020 MACHINE SCREW 2

45 0601821370 RECTIFIER ................................................. 2 .......... REPLACES 0601823240

46 0027104020 MACHINE SCREW 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 67

ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

DCA-85SSJU — ENGINE AND RADIATOR ASSY.

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

DCA-85SSJU — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2925200014 ENGINE ......................................................1 .......... JOHN DEERE 4045TF250

0602011490 FAN BELT 1

2 0602041290 ELEMENT, OIL FILTER ............................... 1 .......... RE59754A

3 0602042590 ELEMENT, FUEL FILTER ............................1 .......... RE62418

4 0602014297 ELECTRIC HEATER .................................... 1 ..........RE29658

5 M2303200303 ENGINE FOOT 2

6 011008020 HEX. HEAD BOLT ....................................... 6 .......... REPLACES 0010312030

7 0040012000 LOCK WASHER 6
8 0605000009 RUBBER SUSPENSION 2
9 0030012000 HEX. NUT 2
10 0040012000 LOCK WASHER 2

11 0602012743 RADIATOR ...................................................1 .......... C2810030001

12 0602011065 CAP .............................................................1 .......... C89C0115010

13 0015908020 HEX. HEAD BOLT 6
14 M2310500503 RADIATOR HOSE 1
15 M2310500603 RADIATOR HOSE 1
16 0605515147 HOSE BAND 3
17 0605515201 HOSE BAND 1

18 0602046582 AIR CLEANER ............................................ 1 ..........FPG082527

0602046365 ELEMENT, AIR CLEANER ..........................1 .......... P828889

19 0602040651 INDICATOR, AIR CLEANER ........................1 ..........RBX002352

20 0602040554 BAND, AIR CLEANER 1
21 M2375200004 BRACKET, AIR CLEANER 1

22 011008020 HEX. HEAD BOLT ....................................... 4 ..........REPLACES 0016908020

23 020108060 HEX. NUT .................................................... 4 ..........REPLACES 0207008000

24 0016908030 HEX. HEAD BOLT 2
25 M2375100003 HOSE, AIR CLEANER 1
26 0605515146 HOSE BAND 1
27 0605515200 HOSE BAND 1
28 0602022563 ADAPTER 1
29 0602022561 90 ELBOW 1
30 0603306590 CONNECTOR 1
31 0603300285 ROCKNUT 1
32 0605511395 VALVE 1
33 0603306395 HOSE JOINT 1

34 0602021070 CAP .............................................................1 ...........10FNTX- S

35 0269200600 DRAIN HOSE 1
36 M9300000103 RESERVE TANK 1
37 M9300100003 CAP, RESERVE TANK 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 69

ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

DCA-85SSJU — ENGINE AND RADIATOR ASSY.

PAGE 70 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

38 0199100175 HOSE 1

39 M2316100114 BRACKET, RESERVE TANK ....................... 1 .......... REPLACES M2316100204

40 011008020 HEX. HEAD BOLT ....................................... 2 ..........REPLACES 0016908020

41 M2260600024 RELAY BRACKET 1

42 012210020 HEX. HEAD BOLT ....................................... 1 ..........REPLACES 0017110020

43 0602202592 RELAY .........................................................1 .......... AT141011

44 020106050 HEX. NUT .................................................... 2 ..........REPLACES 0030006000

45 011808015 MACHINE SCREW ......................................2 .......... REPLACES 0027106015

46 M2483400014 ALTENATOR COVER 1

47 011206020 HEX. HEAD BOLT ....................................... 2 ..........REPLACES 0016906020

48 0602122281 OIL SWITCH ............................................... 1 .......... 1718939011

49 M9200100704 ADAPTER 1

50 0602123282 WATER SWITCH ......................................... 1 .......... 1518183041

51 M9200100404 ADAPTER 1

52 0602060000 BLOWER FAN ............................................. 1 ..........REPLACES 0602060011

53 0602061000 FAN SPACER .............................................. 1 ..........R81911

54 0012110095 HEX. HEAD BOLT 4

55 030210250 LOCK WASHER ...........................................4 .......... REPLACES 0042510000

56 DYNC70025000012 ACTUATOR ..................................................1 .......... REPLACES 0602150093

57 M3356200004 STOPPER BRACKET 1

58 012210020 HEX. HEAD BOLT ....................................... 1 ..........REPLACES 0017110020

59 011206020 HEX. HEAD BOLT ....................................... 1 ..........REPLACES 0017106020

60 0207006000 HEX. NUT 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 71

DCA-85SSJU — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

PAGE 72 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

M2357200062 WIRE HARNESS, ENGINE 1

1 0602120096 TACHOMETER ............................................ 1 .......... 103678

2 0602122093 OIL PRESSURE GAUGE ............................1 .......... 100174

3 0602122272 UNIT, OIL PRESSURE ................................1 .......... 108497

4 0602123092 WATER TEMPERATURE GAUGE ............... 1 .......... 100182

5 0602123261 UNIT, WATER TEMPERATURE ................... 1 .......... 0202500

6 0602121080 CHARGING AMMETER ..............................1 .......... 100158

7 0602125090 FUEL GAUGE ............................................. 1.......... 100176

8 0601831585 PREHEAT BUTTON ....................................1 .......... 44047

0601831586 CAP .............................................................1 .......... 44053

9 0601831395 ENGINE SPEED SWITCH .......................... 1 .......... 7302K36

10 ECU9988N ENGINE CONTROLLER .............................. 1 ..........REPLACES 0602202545

11 82608 SWITCH ...................................................... 1 .......... REPLACES 0601831340

12 0027104035 MACHINE SCREW 2

0030004000 HEX. NUT ....................................................2 .......... REPLACES 0207004000

13 0601810141 PANEL LIGHT..............................................1 .......... 9826800370

14 0601831330 SWITCH, PANEL LIGHT .............................1 .......... 900001

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 73

OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

DCA-85SSJU — OUTPUT TERMINAL ASSY.

PAGE 74 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3230700003 TERMINAL PANEL 1
2 M9220100304 OUTPUT TERMINAL BOLT 5

3 0801830804 TIE BOLT ....................................................5 .......... REPLACES M9220100404

4 0039316000 HEX. NUT 10
5 0040016000 LOCK WASHER 15
6 0041416000 PLAIN WASHER 20

7 0012108035 HEX. HEAD BOLT ...................................... 5 ..........REPLACES 0016908035

8 M2238100003 TERMINAL COVER 1
9 M3236100104 OUTPUT WINDOW 1

10 0605010040 HINGE ........................................................ 2 ..........TH- TM122

11 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT ................................................... 4 .......... REPLACES 0030003000

S8413 PLAIN WASHER ......................................... 4 ..........REPLACES 0041203000

12 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT ................................................... 4 .......... REPLACES 0030003000

13 011106015 HEX. HEAD BOLT ...................................... 2 .......... REPLACES 0016906015

14 011106015 HEX. HEAD BOLT ...................................... 4 .......... REPLACES 0016906015

15 M3236400004 CABLE OUTLET COVER 1
16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1

17 011106015 HEX, HEAD BOLT ...................................... 6 .......... REPLACES 0016906015

18 0601808803 CIRCUIT BREAKER ................................... 2 .......... QUO 120B 1P 20A

19 0601808804 CIRCUIT BREAKER ................................... 3 .......... QOU 250B 2P 50A

20 M1260700304 BREAKER FITTING COVER 1
21 0222100150 CUSHION RUBBER 1

22 011106015 HEX. HEAD BOLT ...................................... 2 .......... REPLACES 0016906015

23 0601812597 RECEPTACLE;GF530EM 125V 20AX2 ...... 2 ...........REPLACES 0601812598

24 0601811034 RECEPTACLE;CS6369 250V 50A; ............. 3 ...........REPLACES 0601812538

25 0021304015 MACHINE SCREW ................................... 10 .......... REPLACES 0027104015

0030004000 HEX. NUT ................................................. 10 .......... REPLACES 0207004000

26 0601815194 TERMINAL BLOCK .................................... 1 .......... 601- GP- 02

27 0021304015 MACHINE SCREW ..................................... 2 .......... REPLACES 0027104015

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 75

BATTERY ASSY.

BATTERY ASSY.

DCA-85SSJU — BATTERY ASSY.

PAGE 76 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 551010280 BATTERY .................................................... 1 .......... REPLACES 0602220187

2 M9310500014 BATTERY SHEET 1
3 M9103000304 BATTERY BAND 1
4 06022209020 BATTERY BOLT SET 2
5 0040006000 LOCK WASHER 2
6 M1346400204 BATTERY CABLE 1
7 M2346400104 BATTERY CABLE 1

8 011008020 HEX. HEAD BOLT ....................................... 1 .......... REPLACES 0016908020

0040508000 TOOTHED WASHER 1
9 CABLE 1
10 0017112025 HEX. HEAD BOLT 1

0040512000 TOOTHED WASHER 1

11 012210020 HEX. HEAD BOLT .......................................1 .......... REPLACES 0017110020

0040510000 TOOTHED WASHER 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 77

MUFFLER ASSY.

MUFFLER ASSY.

DCA-85SSJU — MUFFLER ASSY.

PAGE 78 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602300166 MUFFLER 1

2 012210025 HEX. HEAD BOLT ....................................... 4 .......... REPLACES 0016910025

3 M2335000003 EXHAUST PIPE 1

4 0602325066 CLAMP ........................................................ 1 ......... MOO1432

5 M2333200004 GASKET ..................................................... 1 ......... REPLACES M2333200014

6 0016908040 HEX. HEAD BOLT 4
7 M2330400314 COVER 1
8 M2333399913 BRACKET 1

9 011106015 HEX. HEAD BOLT ....................................... 4 .......... REPLACES 0016906015

10 0602326060 U BOLT SET ............................................... 1 ..........89545K

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 79

FUEL TANK ASSY.

FUEL TANK ASSY.

DCA-85SSJU — FUEL TANK ASSY.

PAGE 80 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2363000102 FUEL TANK 1
2 0605505070 CAP, FUEL TANK 1
3 M3363200104 TANK BAND 2
4 M9310500104 SUPPORTER SHEET 4

5 011008020 HEX. HEAD BOLT ....................................... 2 .......... REPLACES 0016908020

6 0207308000 HEX.NUT 2
7 0222100178 RUBBER SHEET 4
8 M9200000003 DRAIN JOINT 1
9 M9200200004 DRAIN BOLT 1
10 0150000018 O RING 1

11 011206020 HEX. HEAD BOLT ....................................... 2 .......... REPLACES 0016906020

12 M1363400104 DRAIN HOSE 1
13 0605515198 HOSE BAND 2

14 0602042420 FUEL FILTER .............................................. 1.......... PTG15P

15 0602042601 LEAK- OFF LINE ......................................... 1 ..........RE67050

16 0191300450 SUCTION HOSE 1
17 0191301600 SUCTION HOSE 1
18 0191302000 RETURN HOSE 1
19 0605515189 HOSE BAND 1
20 0605515109 HOSE BAND 5
21 0602220911 CLAMP 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 81

ENCLOSURE ASSY.

ENCLOSURE ASSY.

DCA-85SSJU — ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 82 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2415000203 BASE 1
2 M1413400004 UNDER COVER 1

3 011008020 HEX. HEAD BOLT ....................................... 2 .......... REPLACES 0016908020

4 M2425000003 FRONT FRAME 1

M2495100503 ACOUSTIC SHEET 1

5 011008020 HEX. HEAD BOLT ....................................... 6 .......... REPLACES 0016908020

6 M2423200214 COVER, FRONT FRAME 1

M2495100404 ACOUSTIC SHEET 1

7 011008020 HEX. HEAD BOLT .................................... 11 ..........REPLACES 0016908020

8 M2423200313 INNER COVER, FRONT FRAME 1

9 011008020 HEX.HEAD BOLT ....................................... 7 .......... REPLACES 0016908020

10 M2435000203 CENTER FRAME 1
11 M2433000303 CENTER FRAME 1
12 0010114030 HEX. HEAD BOLT 8

030214350 LOCK WASHER .......................................... 8 .......... REPLACES 0040014000

031114260 PLAIN WASHER ......................................... 8 .......... REPLACES 0041214000

13 012212030 HEX. HEAD BOLT .................................... 10 .......... REPLACES 0017112030

14 M2445000103 REAR FRAME 1

M2493300904 ACOUSTIC SHEET 1

15 011008020 HEX. HEAD BOLT ...................................... 4 .......... REPLACES 0016908020

16 M2445300003 REAR COVER 1
17 M2445300103 DUCT, REAR COVER 1

M2495300504 ACOUSTIC SHEET 1
18 M2445300203 DUCT, REAR COVER 1

M2495300004 ACOUSTIC SHEET 1
19 0207006000 HEX. NUT 16

20 011008020 HEX. HEAD BOLT ...................................... 9 .......... REPLACES 0016908020

21 M2443200123 REAR DOOR 1
22 M1443600204 WINDOW PLATE 1

23 020106050 HEX. NUT ................................................... 8 ..........REPLACES 0207306000

952404470 PLAIN WASHER ......................................... 8 .......... REPLACES 0041206000

24 B9114000002 DOOR HANDLE ASS’Y .............................. 1 .......... REPLACES M9113000002

25 0027106016 MACHINE SCREW ..................................... 4 .......... REPLACES 0021806015

0030006000 HEX. NUT 4
26 M9110100204 HINGE 2
27 M9116100004 WASHER 2

28 011008020 HEX. HEAD BOLT ...................................... 3 .......... REPLACES 0016908020

29 0845031504 BLIND PLUG .............................................. 2 .......... REPLACES M9310000004

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 83

ENCLOSURE ASSY.

ENCLOSURE ASSY.

DCA-85SSJU — ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

PAGE 84 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

30 M2463000202 ROOF PANEL 1

M2493500123 ACOUSTIC SHEET 1
31 M2463500114 OVER COVER, FRONT FRAME 1

32 011008020 HEX. HEAD BOLT .................................... 18 .......... REPLACES 0016908020

33 1625165103 BONNET CAP ............................................ 1 ..........REPLACES M9310000103

34 1625165204 CHAIN ASS’Y ............................................. 1 .......... REPLACES M1483600204

35 M2455200103 SPLASHER PANEL 1

M2493300804 ACOUSTIC SHEET 1

36 011208060 HEX. HEAD BOLT ...................................... 4 .......... REPLACES 0016908055

37 011008020 HEX. HEAD BOLT ...................................... 2 .......... REPLACES 0016908020

38 M2455000003 SIDE DOOR 1

M2493400904 ACOUSTIC SHEET 1
39 M2453000603 SIDE DOOR 1

M2493401104 ACOUSTIC SHEET 1
40 M2455000103 SIDE DOOR 1

M2495400304 ACOUSTIC SHEET 1
41 M2455000203 SIDE DOOR 1

M2495400004 ACOUSTIC SHEET 1
42 M2453300503 DUCT 1

M2493401004 ACOUSTIC SHEET 1
43 M2455300003 DUCT 1

M2495400404 ACOUSTIC SHEET 1
44 020706000 HEX. NUT 13

45 B9114000002 DOOR HANDLE ASS’Y ............................... 3 ......... REPLACES M19113000002

46 0027106016 MACHINE SCREW .................................... 12 ......... REPLACES 0021806015

020106050 HEX. NUT .................................................. 12 ......... REPLACES 0030006000

47 M9110100204 HINGE 4
48 M9110100304 HINGE 4
49 M9116100004 WASHER 8

50 011008020 HEX. HEAD BOLT ....................................... 9 ......... REPLACES 0016908020

51 0601850097 DOOR STOPPER 8
52 0027208025 MACHINE SCREW 8

53 0845031504 BLIND PLUG ............................................... 8 ......... REPLACES M9310000004

54 011008020 HEX. HEAD BOLT ....................................... 1 ......... REPLACES 0016908020

0040508000 TOOTHED WASHER 1
55 M2455600004 DOOR BRACKET 1
56 0016906015 HEX. HEAD BOLT 3

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

RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

DCA-85SSJU — RUBBER SEALS ASSY.

PAGE 86 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901580 SEAL RUBBER 2
2 0229200825 SEAL RUBBER 1
3 0228900670 SEAL RUBBER 1
4 0228901090 SEAL RUBBER 4
5 M2492300004 SEAL RUBBER 1
6 0228800665 SEAL RUBBER 1
7 0228900425 SEAL RUBBER 1
8 0228900860 SEAL RUBBER 1
9 0228900630 SEAL RUBBER 1
10 0229200900 SEAL RUBBER 2
11 0229200840 SEAL RUBBER 1
12 0228800770 SEAL RUBBER 2
13 0228800540 SEAL RUBBER 1
14 0228800580 SEAL RUBBER 1
15 0228100550 SEAL RUBBER 1
16 0228100170 SEAL RUBBER 2
17 0228100350 SEAL RUBBER 1
18 0228100360 SEAL RUBBER 1
19 0228100180 SEAL RUBBER 1

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 87

NAME PLATE ASSY.

DCA-85SSJU — NAMEPLATE AND DECAL ASSY.

PAGE 88 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

DCA-85SSJU — NAMEPLATE AND DECAL ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 9039209064 DECAL; START CONTACT .............................................. 1 ......... S- 4468

2 C9522100003 DECAL; CAUTION ........................................................... 2 ......... C9221 0000

3 C9595300004 DECAL; CAUTION ........................................................... 1 ......... C9053 0000

4 M1550000204 DECAL; NOTE ................................................................. 1 ......... M1500 0020

5 M1550000703 DECAL; AUXILIARY OUTPUT ......................................... 1 ......... M1500 0070

6 M2552000104 DECAL; NOTE ................................................................. 1 ......... M2520 0010

7 M2552000203 DECAL; ENGINE OPERATING ........................................ 1 ......... M2520 0020

8 M2552000303 DECAL; GENERATOR CONTROL................................... 1 ......... M2520 0030

9 M3552000103 DECAL; OPERATING PROCEDURES ............................ 1 ......... M3520 0010

10 M9500000004 DECAL; OIL DRAIN PLUG ............................................... 1 ......... M9000 0000

11 M9500100004 DECAL; WATER ............................................................... 1 ......... M9001 0000

12 M9500300004 DECAL; - .......................................................................... 1 ......... M9003 0000

13 M9500300104 DECAL; + ......................................................................... 1 ......... M9003 0010

14 M9500500004 DECAL; DIESEL FUEL .................................................... 1 ......... M9005 0000

15 M9500500104 DECAL; FUEL DRAIN PLUG ........................................... 1 ......... M9005 0010

16 M9503000004 DECAL; WARNING MOVING PARTS............................... 2 ......... M9030 0000

17 M9503000103 DECAL; WATER - OIL CHECK ........................................ 1 ......... M9030 0010

18 M9503100004 DECAL; WARNING HOT COOLANT ............................... 1 ......... M9031 0000

19 M9503200004 DECAL; WARNING ENGINE EXHAUST .......................... 1 ......... M9032 0000

20 M9510100004 DECAL; CAUTION HOT PARTS....................................... 1 ......... M9101 0000

21 M9510200002 DECAL; MQ ..................................................................... 1 ......... M9102 0000

22 M9520000004 DECAL; GROUND ........................................................... 1 ......... M9200 0000

23 M9520000104 DECAL; AMMETER CHANGE- OVER SWITCH .............. 1 ......... M9200 0010

24 M9520000204 DECAL; VOLTMETER CHANGE- OVER SWITCH........... 1 ......... M9200 0020

25 M9520100004 DECAL; WARNING ELECTRIC SHOCK HAZARD .......... 2 ......... M9201 0000

26 M9520100204 DECAL; CAUTION ........................................................... 1 ......... M9201 0020A

27 M9520100304 DECAL; SAFETY INSTRUCTIONS .................................. 1 ......... M9201 0030

28 M9520100404 DECAL; DANGER HIGH VOLTAGE ................................. 1 ......... M9201 0040

29 M9520100503 DECAL; WARNING .......................................................... 1 ......... M9201 0050

30 M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ................. 1 ......... M9292 0000

31 0600500090 EMBLEM 1

0021106015 MACHINE SCREW 2
32 M2560100003 STRIPE; WHISPERWATT 1
33 M2560100103 STRIPE; MQ POWER 2
34 M2560100203 STRIPE 2
35 M2560100403 STRIPE 2
36 M2562100004 STRIPE; 85 2

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 89

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 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 shor tage 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 accepted and credit
will be allowed, subject to the following
provisions:

1. A Returned Material Authorization must
be approved by Multiquip prior to shipment.

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

a. The parts numbers and descriptions

must match the current parts price
list.

b. The list must be typed or computer

generated.

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

the return.

d. The list must reference the sales

order(s) or invoice(s) under which
the items were originally purchased.

e. The list must include the name and

phone number of the person
requesting the RMA.

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

4. Freight is at the sender’s expense. All

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any material

8. Such material will be held for 5 working

9. Credit on returned parts will be issued at

10. In cases where an item is accepted for

11. Credit issued will be applied to future

PRICING AND REBATES

parts must be returned freight prepaid to
Multiquip’s designated receiving point.

condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.

a. Obsolete parts. (If an item is listed

in the parts price book as being
replaced by another item, it is
obsolete.)

b. Any parts with a limited shelf life

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

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.
g. Decals and paper products.

h. Items purchased in kits.

received that is not acceptable.

days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.

dealer net price at time of the original
purchase, less a 15% restocking charge.

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.

purchases only.

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.

Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 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.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under 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 warranties, express or implied, 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 not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.

PAGE 90 — DCA-85SSJU — PARTS AND OPERATION MANUAL — REV. #2 (12/21/01)

NOTE PAGE

DCA-85SSJU — PARTS AND OPERATION MANUAL— REV. #2 (12/21/01) — PAGE 91

PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700
FAX: [phone]

MAIN

800/421-1244 or 310/537-3700
FAX: [phone]

Manufactured for Multiquip Inc.

DENYO MANUFACTURING CO., USA

by

MULTIQUIP INC.

POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [e-mail]
WWW: multiquip.com

Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX

Atlanta • Boise • Dallas • Houston • Newark