MULTIQUIP Power Ultra-Silent DCA-85USJ Parts Manual

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Page 1

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

SERIES

MODEL DCA-85USJ

GENERATOR

PARTS LIST NO. M2870400004

Revision #0 (09/17/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

Page 2

PAGE 2 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 3

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-85USJ Ultra Silent Generator

. Multiquip Inc. reserves the right to discontinue or change specifications, design or

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 3

Page 4

TABLE OF CONTENTS

MQ POWER DCA-85USJMQ POWER DCA-85USJ

MQ POWER DCA-85USJ

MQ POWER DCA-85USJMQ POWER DCA-85USJ ULUL

TRA-SILENT GENERATRA-SILENT GENERA

TRA-SILENT GENERA

ULUL

TRA-SILENT GENERATRA-SILENT GENERA

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

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

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

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

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ................................................. 20

Engine Operating Panel ............................................. 22-23

Output Terminal Panel Familiarization ........................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Gauge Reading ............................................................... 29

Output Terminal Panel Connections ........................... 30-31

Pre Setup .................................................................. 32-35

Generator Start-up Procedure (Manual) ..................... 36-38

Generator Start-up Procedure (Auto Mode) .................... 39

Generator Shut-Down Procedure .................................... 40

Maintenance .............................................................. 41-43

Trailer Maintenance.................................................... 44-47

Trailer Wiring Diagram ..................................................... 48

Generator Wiring Diagram ............................................... 49

Engine Wiring Diagram ................................................... 50

Generator Troubleshooting .............................................. 51

Engine Controller Troubleshooting ...................................52

TORTOR

TOR

TORTOR

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

Generator Assembly .................................................. 56-57

Control Box Assembly ............................................... 58-61

Engine & Radiator Assembly..................................... 62-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure #1 Assembly ............................................ 74-77

Enclosure #2 Assembly ............................................ 78-81

Rubber Seals Assembly ............................................ 82-83

Nameplate and Decals .............................................. 84-87

Terms and Condition of Sale — Parts ............................ 88

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 5

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ 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:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

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.

at no charge for freight

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 5

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

Page 6

DCA-85USJ — SPECIFICATIONS

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)WK2.27(AVK2.09WK66

)WK6.56(AVK28WK06

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V021

.2(WK8.4

)2xWK4

snoitacificepSenignE

suonorhcnysepytdetcetorpnepo,detalitnevfles,dleifgnivloveR

ledoM

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tuptuOdetaR

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degrahc-obrut,noitcejnitcerid,delooc-retaw,elcyc4

)mm721xmm601(.ni5x.ni91.4

mpr0081/PH201

)cc005,4(.ni.uc572

CDV2

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)sretil2.31(.lag5.3

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)sretil084(.lag721

)L5.41(.lag8.3 daol4/3

72puorGICBV21

PAGE 6 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 7

DCA-85USJ — DIMENSIONS (TOP, SIDE AND FRONT)

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 7

Figure 1. Dimensions

Page 8

DCA85USJ — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-85USJ

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

ULTRA-SILENT™ GENERATOR.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

Page 9

DCA85USJ — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 9

Page 10

DCA-85USJ — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

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

The following safety guidelines should always be used when operating the DCA-85USJ Generator:

General Safety:

■

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

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

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.

or even

DEATH

! This equipment is to be

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

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

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

■

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

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. 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.

bodily harm or even death.

NEVER

operate the generator in any

■

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. Unauthorized equipment modification will void all warranties.

■

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

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

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

DO NOT leave the generator running in the unattended.

Refer to the engine technical questions or information.

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

John Deere Engine Owner's Manual

manual mode

for

PAGE 10 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 11

DCA-85USJ — RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

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

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(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.

The following safety recommendations should also be followed:

To avoid these hazards: NEVER use damaged or worn cables when connecting

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

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 5.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

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. ALWAYS have a licensed electrician perform the installation

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 11

Page 12

DCA-85USJ — RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■

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.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the 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.

■

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

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

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

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.

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

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

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

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 12 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 13

DCA-85USJ — RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

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

■

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

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

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

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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 chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

DOT Requirements include the following:

z z

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

Page 14

DCA-85USJ — GENERATOR DECALS

The DCA-85USJ generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 14 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Figure 2. Generator Decals

Page 15

DCA-85USJ — GENERATOR DECALS

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 15

Figure 3. Generator Decals (Cont inued)

Page 16

DCA-85USJ — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 17

DCA-85USJ — INSTALLATION

Outdoor Installation

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

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

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

CAUTION - EXHAUST HAZARD

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.

Indoor Installation

Generator Grounding

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

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

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

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

a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 4) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect 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 aminimum of 8 ft. into the ground.

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.

NOTE

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

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 17

Page 18

DCA-85USJ — GENERAL INFORMATION

DCA-85USJ Series Familiarization Generator

The MQ Power Model DCA-85USJ is a 65.6 kW

generator

(Figure 5) 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 Operating Panel

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

■■

■

Tachometer

■■

■

Water Temperature Gauge

■■

Oil Pressure Gauge

■

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Pre-heat Lamp

■■

■

Panel Light/Panel Light Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

■■

■

Fuel Leak Detected Alarm Lamp

■■

Generator Control Panel

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

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

3-Pole, 250 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Selector Switch

■■

Output Terminal Panel

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

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

Open Delta Excitation System

The DCA-85USJ generator is equipped with the state of the

Open-Delta

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

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

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

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

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

Engine

The DCA-85USJ is powered by a 4 cycle, water cooled, direct injection, turbocharged

Diesel Engine

performance requirement for the generator. Reference Table 1 for engine specifications.

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

Electric Governor System

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

Extension Cables

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 5) as a guide for selecting proper extension cable size.

" excitation system. The open delta system

fixed ceiling

" and responds

John Deere Model 4045TF275

. This engine is designed to meet every

PAGE 18 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 19

DCA-85USJ — MAJOR COMPONENTS

Figure 5. Major Components

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DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 19

Page 20

NOTE PAGE

PAGE 20 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 21

DCA-85USJ — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

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

Generator Control Panel

(Figure 6).

1. Main Circuit Breaker – This three-pole, 250A main breaker is provided to protect the the

Terminal Lugs

from overload.

U,V, and W Output

2. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

3. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

4. 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

NOTE

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

5. AC Voltmeter – Indicates the output voltage present at the

U,V, and W Output Terminal Lugs

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

In the event of a short circuit or over current condition, it will automatically trip the 60 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

be switched off.

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

7. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 21

Page 22

DCA-85USJ — ENGINE OPERATING PANEL

PAGE 22 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Figure 7. Engine Operating Panel

Page 23

DCA-85USJ — ENGINE OPERATING PANEL

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

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

2. Panel Light Switch – When activated will turn on control panel light.

3. Oil Pressure Gauge – During normal operation this gauge be should read between 35 to 65 psi. When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

4. Water Temperature Gauge – During normal operation this gauge be should read between 180° and 221°F.

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. Pre-Heat Lamp – As the engine cranks, this lamp will illuminate to indicate automatic preheating of the engine. When the lamp turns off, the engine has been preheated and will start automatically.

9. Fuel Leak Detected Alarm Lamp – This lamp will illuminate when a leak in the fuel tank containment enclosure is detected.

10. Auto On/Off Engine Controller (MPEC) – This controller has a vertical row of status LED's (inset), 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.

Engine Operating Panel

(Figure 7).

During engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the

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

A. MPEC Control Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure has

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has

E. Overspeed Shutdown – Indicates the engine is running

F. Engine Running – Indicates that engine is running at

cranking cycle

Over Speed Protection

running of the unit. If this switch is set to the OFF/RESET position, the unit will not run. When this switch is set to the MANUAL position, the generator will start immediately.

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

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

temperature has exceeded 239°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

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

at an unsafe speed. This is considered a

a safe operating speed.

fault.

, The MPEC will attempt to crank the

Over Crank Protection

mode.

major

fault.

major

fault.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 23

Page 24

DCA-85USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

lugs.

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

Two (2) 120V GFCI receptacles @ 20 amp

■

■■

Two (2) GFCI Circuit Breakers @ 20 amps

■

■■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■

■■

NOTE

Terminal legs “O” and “Ground” are considered

bonded grounds

” (Figure 8) is provided with the

PAGE 24 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Figure 8. Output Terminal Panel

Page 25

DCA-85USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

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

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

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

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

voltage regulator control knob

increase

decrease

Figure 11. Voltage Regulator Control Knob

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

(Figure 11) on the

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

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can when the voltage selector switch is placed in the

only

be accessed

single-

phase 240/120 position.

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 25

Page 26

DCA-85USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Lugs

or the convienience receptacles. (See Figure 13). Make sure to read the operation manual before attempting to connect a load to the generator.

Ouput Terminal

Blower Fan

This unit has an intake fan located at the rear of the machine to draw outside air into the cabinet to cool the engine. The fan has a 10 amp AC fuse located beneath the

Selector Switch

To protect the output terminals from overload, a

main

3-pole, 250A

circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

DANGER - ELECTROCUTION HAZARDS

Voltage

(Figure 15).

Figure 15. Blower Fan Fuse

Figure 13. Connecting Loads

Over Current Relay

over current relay

(Figure 14) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the

reset button

on the over current relay must be pressed. The over current relay is located in the control box.

This fuse has current running through it any time the engine is running. This fuse is NOT connected to the main circuit breaker of the generator. Attempting to replace the fuse with the engine and/or generator operating could result in

bodily harm

electrocution

and

severe

. ALWAYS turn the unit completely off before attempting to replace or handle this fuse.

Figure 14. Over Current Relay

PAGE 26 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 27

DCA-85USJ — LOAD APPLICATION

Single Phase Load

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

frequency

Three Phase Load

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

, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 4 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

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■■

■

When connecting a resistance load such as an

■■

incandescent lamp or electric heater, a capacity of up to

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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.

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DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

electrical system may occur without this transfer switch.

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

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

licensed electrician

must install an

. Serious damage to the building’s

isolation

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 27

Page 28

DCA-85USJ — GENERATOR OUTPUTS

Voltage Selector Switch

voltage selector

The

switch (Figure 16) is located above

the output terminal panel’s

Hard Wire Hook-up Panel

Generator Amperage

Table 7 describes the generator’s current output capability

. It

for both 1Ø-phase and 3Ø phase applications.

has been provided for ease of voltage selection.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 3 twist lock auxilliary receptacles.

Tables 8 and 9 show what amount of current is available at the GFCI receptacles when the output terminals and twist

Figure 16. Voltage Selector Switch

Voltage Selector Switch Locking Button

lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch,

hold

the

red button

located at the bottom of the switch.

press

and

CAUTION - CHANGING VOLTAGES

NEVER change the position of the

voltage selector switch

while the engine is running. ALWAYS place circuit breaker in the open position before selecting voltage.

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Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the

voltage selector

switch (Figure 15). To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the

knob

located on the control panel.

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PAGE 28 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

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Page 29

DCA-85USJ — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

Output terminals lugs

Before taking a reading off either gauge, set the

Selector Switch

the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/ 139V position on the voltage selector switch.)

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

Voltage

(Figure 17) to the position which produces

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 20) to activate the (Figure 21) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the U and read the AC Ammeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Figure 21. AC Ammeter (Amp reading on U lug)

For 3Ø 208V/1Ø,120V, place

NOTE

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch

setting (Figure 18) to activate the (Figure 19) and read the available voltage between the two lugs.

For example, to measure the voltage between the W and U terminal lugs, set the to W-U and read the

AC Voltmeter Change-Over Switch

AC Voltmeter Gauge

the Voltage Selector Switch in the 3 Phase 340/139 position.

to the appropriate

AC Voltmeter Gauge

NOTE

The

ammeter

show a reading when the

Output Terminal Lugs

connected to a load and in use.

gauge will only

are

Figure 18. AC Voltmeter

Change-Over Switch

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 29

Figure 19. AC Voltmeter Gauge

(Volt reading on W-U Lug)

Page 30

DCA-85USJ — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the

Terminal Lugs

dent on the position of the adjustment of the

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

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139

position as shown in Figure 22.

.. The voltages at the terminals are depen-

Voltage Selector Switch

Voltage Regulator Control Knob

Output

and the

range

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 25.

2. Connect the load wires to the shown in Figure 26.

Use this position for 3Ø-208 or 1Ø120V.

Figure 25. Voltage Selector Switch 3Ø-208V/1Ø-120V Three-Phase Position

Output Terminal Lugs

Figure 22. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the shown in Figure 22.

Figure 23. Output Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Output Terminal Lugs

Figure 26. Output Terminal Lugs

3Ø-208V/120V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

To achieve a 3Ø 208V output the voltage selector switch

NOTE

must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V.

Figure 24. Voltage Regulator Knob (139V/240V)

PAGE 30 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 31

DCA-85USJ — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the shown in Figure 28.

Output Terminal Lugs

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 29.

Figure 29. Voltage Selector Switch 240/120V

2. Connect the load wires to the shown in Figure 30.

Single-Phase Position

Output Terminal Lugs

Figure 28. UVWO Terminal Lugs

480/277V Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 31

Figure 30. UVWO Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 25) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Page 32

DCA-85USJ — PRE-SETUP

Circuit Breakers

Fuel Check

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

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

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

receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two notches (Figure 31) on the dipstick. See Table 10 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 31. Engine Oil Dipstick

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

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

The generator unit has an internal fuel tank located at the bottom of the cabinet (Figure 32). with clean and fresh tanks beyond their capacities.

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

hot

engine can cause a

ALWAYS

#2 diesel fuel.

fire

explosion

fill the fuel tank

DO NOT fill the fuel

■■

■

API Service Classification CC/SC

■■

■

API Service Classification CC/SD

■■

■

API Service Classification CC/SE

■■

■

API Service Classification CC/SF

■■

Table 10. Recommended Motor Oil

OIL: SAE

5W30

ARCTIC OIL

122

104

-14

-22

-40

10W40

032

-10

-4

-20

-30

-40

PAGE 32 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

10W/40

15W30

20W40

10W

10W30

Figure 32. Internal Fuel Tank System

Page 33

DCA-85USJ — PRE-SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 33).

CAUTION - REFUELING THE GENERATOR

ALWAYS

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

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 34).

Figure 34. Fueling the Generator

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

3. NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 35).

when

Figure 35. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 33

Figure 36. Fuel Expansion

Page 34

DCA-85USJ — PRE-SETUP

Coolant (John Deere Antifreeze/Summer Coolant/Water)

John Deere recommends John Deere Antifreeze/Summer Coolant for use in thier engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the John Deere Engine Owner's Manual for further details.

WARNING - BURN HAZARDS

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

If adding coolant/antifreeze mix to the

accordance with the John Deere Engine Owner's Manual.

radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

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

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 11 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 37) when depressed with the thumb as shown below.

is always between the "H" and the "L" markings.

battery terminal disconnected.

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When operating in freezing weather, be certain the proper amount of antifreeze (Table 12) has been added.

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CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

PAGE 34 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

less than 50%.

Page 35

DCA-85USJ — PRE-SETUP

Battery

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

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

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

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

Battery Cable Installation ALWAYS be sure the battery cables (Figure 38) are properly

connected to the battery terminals as shown below. The Red Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal of the battery.

CAUTION - BATTERY SERVICING SAFETY

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the the MANUAL position. ALWAYS make sure that the

Control Switch

connecting the battery.

2. Place a small amount of battery terminal treatment

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

NOTE

CAUTION - BATTERY SERVICING SAFETY

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

Alternator

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

MPEC Control Switch

is in either

MPEC

is in the OFF/RESET position when

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.

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 38. Battery Connections

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 35

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrision and damage the alternator.

Wiring

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

Piping and Hose Connection

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

If any hose ( immediately.

fuel

oil

) lines are defective replace them

Page 36

DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting 4. Close all engine enclosure doors (Figure 40).

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

2. Connect the load to the

manually start the engine with the

auxiliary

(Figure 39) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

and

aux.

receptacles or

Terminal Lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

as shown in Figure 13. These load

main, GFCI

circuit breakers

the

Output

5. Place the

Figure 40. Engine Enclosure Doors

voltage selector switch

in the desired voltage position (Figure 41).

Figure 41. Voltage

Selector Switch

3. The output terminal lugs are protected by a plastic cover. Remove this cover to gain access to the terminals. Tighten terminal nuts securely to prevent load wires from slipping out.

PAGE 36 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 37

DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)

Starting (Manual)

8. Place the position to start the engine (Figure 42).

In cold weather conditions, placing the

Switch

the engine AUTOMATICALLY. The (Figure 43) will turn off when the engine has started.

7. Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

MPEC Control Switch

Figure 42. MPEC Control Switch

(Manual Position)

in the MANUAL

MPEC Control

in the MANUAL position will preheat and start

Preheat Lamp

9. The generator's frequency meter (Figure 45) should be displaying the 60 cycle output frequency in HERTZ.

Figure 45. Frequency Meter (Hz)

10. The generator's AC-voltmeter (Figure 46) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 47) to increase or decrease the desired voltage.

Figure 43. Pre-Heat Lamp

8. Verify that the Engine Running status LED on the MPEC unit (Figure 44) is ON (lit) after the engine has been started.

Figure 44. Engine

Running LED (ON)

Figure 46. Voltmeter

Figure 47. Voltage Adjust Control Knob

11. The ammeter (Figure 48) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 48. Ammeter (No Load)

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 37

Page 38

DCA-85USJ — GENERATOR START-UP PROCEDURE (MANUAL)

12. The engine oil pressure gauge (Figure 49) will indicate the oil pressure (kg/ cm2) of the engine. Under normal operating conditions the oil pressure is approximately 35~65 PSI.

Figure 49. Oil Pressure Gauge

13. The

14. The

coolant temperature gauge

the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit (

Figure 50. Coolant Temperature Gauge

tachometer gauge

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

(Figure 51) will indicate the

(Figure 50) will indicate

Green Zone

15. Place the ON position (Figure 52).

16. Observe the generator's ammeter (Figure 53) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

main, GFCI

Figure 52. Main, Aux. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers in the

Figure 51. Engine Tachometer Gauge

PAGE 38 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Figure 53. Ammeter (Load)

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

Page 39

DCA-85USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

building’s electrical system may occur without this transfer switch.

must install an

. Serious damage to the

CAUTION - BACKUP GENERATOR USE

licensed

isolation

1. Perform steps 1 through 5 in the

as outlined in the

2. Place the

position .

3. Continue to follow the steps outlined in the

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.

When the generator is set in the

AUTO mode, the generator will

NOTE

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

in the event of

Before Starting

Manual Starting Procedure

MPEC Control Switch

Figure 54. MPEC Control Switch (AUTO)

(Figure 54) in the AUTO

Manual Start-

procedure (start at step 9).

section .

WARNING - AUTO MODE MAINTENANCE

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.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 39

Page 40

DCA-85USJ — GENERATOR SHUT-DOWN PROCEDURE

WARNING -

NEVER stop the engine suddenly except in an emergency. DO NOT use the emergency stop switch a as method of

shutting down the generator. This switch is ONLY to be used in the event of an emergency.

Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 39 to the OFF position.

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

4. Place the

OFF/RESET position.

SHUTTING DOWN THE GENERATOR

MPEC Control Switch

(Figure 55) to the

Emergency Shutdown Procedure

1. To shut-down the engine in the event of an emergency, switch the breakers to OFF position.

2. Place the the OFF/RESET position.

MAIN, GFCI

MPEC Control Switch

and

LOAD

(Figure 39) circuit

switch (Figure 55) to

Figure 55. MPEC Control Switch (Off/Reset)

5. Verify that the are OFF (not lit).

6. Remove all loads from the generator.

all

status LED on the MPEC display

PAGE 40 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 41

DCA-85USJ — MAINTENANCE

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General Inspection

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

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

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

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

Service Daily

If the engine is operating in very conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more

frequently

Fuel Addition

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

Removing Water from the Fuel Tank

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

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

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 41

dusty

if these conditions exists.

dry grass

Page 42

DCA-85USJ — MAINTENANCE

Air Removal

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

Engine Manual

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 33.

Replacing Oil Filter

■■

Remove the old oil filter.

■

■■

■

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

■■

■

Install the new oil filter.

■■

■

After the oil cartridge has been replaced, the engine oil

■■

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

Replacing Fuel Filter

for details.

John Deere

Flushing Out Radiator and Replacing Coolant

■■

■

Open both cocks located at the crankcase side and at

■■

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

■■

■

Check hoses for softening and kinks. Check clamps for

■■

signs of leakage.

■■

Flush the radiator by running clean tap water through

■

■■

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

■■

■

Tighten both cocks and replace the overflow tank.

■■

Replace with coolant as recommended by the engine

■

■■

manufaturer.

■■

■

Close radiator cap tightly.

■■

WARNING - BURN HAZARDS

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

cool

when flushing out

■■

■

Replace the fuel filter cartridge with new one every 500

■■

hours or so.

■■

■

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

■■

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

■■

■

Vent any air.

■■

Generator Storage

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

■■

■

Fill the fuel tank completely. Treat with a fuel stabilizer

■■

if necessary.

■■

■

Completely drain the oil from the crankcase and refill if

■■

necessary with fresh oil.

■■

■

Clean the entire generator, internal and external.

■■

■

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

■■

■

Disconnect the battery.

■■

■

Make sure engine coolant is at proper level.

■■

■

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

■■

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

PAGE 42 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 43

DCA-85USJ — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 56). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 5).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 43

Figure 56. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections

Page 44

DCA-85USJ — TRAILER MAINTENANCE

Trailer Maintenance

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

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

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-85USJ Ultra-Silent Generator.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

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

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

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

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

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

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 17 and Figure 59 and sequence.

13. Axle - Indicates the maximum weight the axle can sup- port in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

for lug nut tightening

5. Frame Width - Measurement is from fender to fender

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

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

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

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

PAGE 44 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 45

DCA-85USJ — TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 57) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 57 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 as listed below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate the

Figure 57. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

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

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

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

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

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DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 45

Page 46

DCA-85USJ — TRAILER MAINTENANCE

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.

Suspension

leaf suspension

The (Figure 58) 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

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 16.

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

CAUTION - REPAIRING TRAILER WHEELS

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.

springs and associated components

Figure 58. Major Suspension Components

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

TABLE 15. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber or overloading.

Wheel lockup & tire skidding.

SOLUTION

Adjust pressure to particular load per tire manufacturer.

Adjust pressure to particular load per tire manufacturer. Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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PAGE 46 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 47

DCA-85USJ — TRAILER MAINTENANCE

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 59). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 17.

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

stnemeriuqeReuqroTeriT.71elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 47

NOTE

Figure 59. Wheel Lug Nuts

Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Page 48

DCA-85USJ — TRAILER WIRING DIAGRAM

Figure 60. Trailer/Towing Vehicle Wiring Diagram

PAGE 48 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 49

DCA-85USJ — GENERATOR WIRING DIAGRAM

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 49

Figure 61. Generator Wiring Diagram

Page 50

DCA-85USJ — ENGINE WIRING DIAGRAM

Figure 62. Engine Wiring Diagram

PAGE 50 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 51

DCA-85USJ — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 51

Page 52

DCA-85USJ — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve )dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

nosithgildeepsrevO

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

PAGE 52 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipci

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenign

sujdA

Page 53

NOTE PAGE

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 53

Page 54

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.

If more than one of the same

NOTE

reference number is listed, the last one listed indicates newest (or latest) part available.

The contents of this catalog are subject to change without notice

, #, +,

PAGE 54 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 55

DCA-85USJ — SUGGESTED SPARE PARTS

DCA-85USJ ULTRA-SILENT GENRATOR

W/JOHN DEERE 4045TF275 DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

5 ......... 0602041292 ........ FILTER, OIL

5 ......... 0602042594 ........ FILTER, FUEL, PRIMARY

5 ......... 0602042595 ........ FILTER, FUEL, FINAL

3 ......... 0602046377 ........ ELEMENT, AIR

1 ......... 0602011493 ........ BELT, FAN

1 ......... 0605505070 ........ CAP. FUEL TANK

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

1 ......... 0602123261 ........ UNIT, WATER TEMPERATURE

2 ......... 0601802149 ........ FUSE, 10A

1 ......... 0602123282 ........ SENDER, WATER SWITCH (ENGINE SIDE)

1 ......... 0602122281 ........ SENDER, OIL SWITCH (ENGINE SIDE)

NOTE

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 55

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

Page 56

GENERATOR ASSY.

DCA-85USJ — GENERATOR ASSY.

PAGE 56 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 57

DCA-85USJ — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B6110000102 ROTOR ASSY. ........................................... 1 .......... INCLUDES ITEMS W/

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10 1-11 1-12 1-13 1-14 1-15 1-16 2 M2163400003 COUPLING RING 1 3 0343204170 HEX, HEAD BOLT 8 4 0043604000 SPRING WASHER 8

5 B6130000303 STATOR ASSY. ......................................... 1 .......... B6134000304

6 0845041804 GROMMET 2 7 8101315202 END BRACKET 1

8 8101350013 FIELD ASSY. EXCITER ............................ 1 .......... B6134000304

9 0012110070 HEX, HEAD BOLT 4 10 0042610000 SPRING WASHER 4 11 0041210000 PLAIN WASHER 4 12 0017110035 HEX, HEAD BOLT 6 13 8101310014 COVER, BEARING 1 14 8131312014 GASKET, BEARING 1 15 0017106012 HEX, HEAD BOLT 6 16 8101331003 COVER, END BRACKET 1 17 0017106012 HEX, HEAD BOLT 4 18 8101333003 COVER, END BRACKET 1 19 0340406040 HEX, HEAD BOLT 1 20 0041206000 PLAIN WASHER 1 21 0012810030 HEX, HEAD BOLT 12 22 8111332014 COVER, FAN 1 23 0340406040 HEX, HEAD BOLT 1 24 0041206000 PLAIN WASHER 1 25 0600815000 NUT 1 26 0605000010 RUBBER SUSPENSION 2 27 0030012000 HEX, NUT 2 27A 0040012000 SPRING WASHER 2 27B 0041212000 PLAIN WASHER 2

28 0070506306 BEARING .................................................. 1 .......... 6306ZZ

8101070033 FAN 1 0012810035 HEX, HEAD BOLT 8 8101611004 COUPLING DISK 5

0012110030 HEX, HEAD BOLT 8 0042510000 SPRING WASHER 8

8101026013 SET PLATE, RECTIFIER .......................... 1 .......... MUST PURCHASE ROTOR ASSY.

0601821349 RECTIFIER ............................................... 2 .......... PT3610

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

8001020004 INSULATOR WASHER 1

8001020504 INSULATOR WASHER 1

0010110020 HEX, HEAD BOLT 4

0040010000 SPRING WASHER 4

0601000209 BALANCING WEIGHT KIT 1

0071906311 BEARING .................................................. 1 .......... 6311DDUC3

FIELD ASSY. 1

BALANCING PLATE .................................. 1 .......... MUST PURCHASE ROTOR ASSY.

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 57

Page 58

CONTROL BOX ASSY.

DCA-85USJ — CONTROL BOX ASSY.

PAGE 58 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 59

DCA-85USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2213000502 CONTROL BOX 1 2 0330000180 EDGING 2

3 0601808822 CIRCUIT BREAKER ........................................ 1 ............ KAF3625010393P 250A

4 0021005080 MACHINE SCREW 4

5 0601823863 RELAY UNIT .................................................... 2 ............ MSA9013A

6 0027104016 MACHINE SCREW 4

7 0601820671 AUTOMATIC VOLTAGE REGULATOR .............. 1 ............ NTA-5A-2DB

8 0027105016 MACHINE SCREW 4

9 0601806118 CURRENT TRANSFORMER ........................... 3 ............ 814-943 200/5A

10 0027106016 MACHINE SCREW 6

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

12 0601820846 OVER CURRENT RELAY ................................ 1 ............ LA7D1064

13 0027104016 MACHINE SCREW 2 13A 0207004000 HEX, NUT 2 14 M3213500013 CONTROL BOX COVER 1 15 0016906016 HEX, HEAD BOLT 4

16 M3270100104 SELECTOR SWITCH ...................................... 1 ............ XUSS01574

........................................................................................ INCLUDES ITEMS W/

16A*TBD KNOB, SELECTOR SWITCH 1 17 M3276600004 SPACER 8 18 M3213600503 SWITCH BRACKET 1 19 0330000330 EDGING 2 20 0027104016 MACHINE SCREW 4 21 0016906016 HEX, HEAD BOLT 6 22 M3213600604 SWITCH COVER 1 23 0016906016 HEX, HEAD BOLT 4 24 0016906016 HEX, HEAD BOLT 10 24A 0040506000 TOOTHED WASHER 1 25 M2223000403 CONTROL PANEL 1

26 0601807641 FREQUENCY METER .................................... 1 ............ FCF-6 45~65Hz 240V

27 0601808988 AC AMMETER ................................................ 1 ............ ACF-6 0~200A/400A:5A

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

29 0601806849 AC VOLTMETER ............................................. 1 ............ SCF-6 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 ............ 25N

33 0602202593 CONTROLLER ................................................ 1 ............ ECU(CAN)

34 0601831340 SWITCH .......................................................... 1 ............ 7562K4

35 0027104035 MACHINE SCREW 2 35A 0207004000 HEX, NUT 2

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 59

Page 60

CONTROL BOX ASSY.

DCA-85USJ — CONTROL BOX ASSY.

PAGE 60 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 61

DCA-85USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

36 0602103092 PREHEAT LAMP ............................................. 1 ............ PL-05

0601810245 BULB 1

37 0602120096 TACHOMETER ................................................ 1 ............ 111812

38 0602122093 OIL PRESSURE GAUGE ................................ 1 ............ 100174

39 0602123092 WATER TEMPERATURE GAUGE ................... 1 ............ 100182

40 0602121080 CHARGING AMMETER .................................. 1 ............ 100158

41 0602125090 FUEL GAUGE.................................................. 1 ............ 100176

42 0601810141 PANEL LIGHT .................................................. 1 ............ 98268-00370

43 0601831330 SWITCH, PANEL LIGHT ................................. 1 ............ 90-0001

44 M1223100004 STOPPER 1 45 M3223100004 STOPPER 1 46 0027105010 MACHINE SCREW 4 47 0027105010 MACHINE SCREW 4 48 M9220100004 SET SCREW 2 49 0080200007 SNAP RING 2

50 0602202592 STARTER RELAY ............................................ 1 ............ AT141011

51 0027106016 MACHINE SCREW 2 52 LY-2D DC12V RELAY 1 52A PTP08A-E BASE 2 52B PYCA1 CLIP 4 53 0027104020 MACHINE SCREW 2

54 0601823240 RECTIFIER ..................................................... 1 ............ DE4503

55 LY2D US12VDC RELAY 1 56 0027104020 MACHINE SCREW 2

57 0602122272 UNIT, OIL PRESSURE .................................... 1 ............ 108497

58 0602123261 UNIT, WATER TEMPERATURE ....................... 1 ............ 02025-00

59 M2246700904 WIRE HARNESS, GENERATOR 1 60 M3357201102 WIRE HARNESS, ENGINE 1

61 0601802149 FUSE ............................................................... 2 ............ F-106510A

62 0601823240 RECTIFIER ..................................................... 1 ............ DE4503

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 61

Page 62

ENGINE & RADIATOR ASSY.

DCA-85USJ — ENGINE & RADIATOR ASSY.

PAGE 62 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 63

DCA-85USJ — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2923200014 ENGINE, JOHN DEERE ................................. 1 ............ 4045TF275

1-1 0602041292 CARTRIDGE, OIL FILTER, JOHN DEERE ...... 1 ............ RE504836

1-2 0602042595 CARTRIDGE, FUEL FILTER, JOHN DEERE .. 1 ............ RE509031

1-3 0602011494 FAN BELT, JOHN DEERE ............................... 1 ............ 240P

2 0602060004 BLOWER FAN, JOHN DEERE ........................ 1 ............ RE47518

3 0602061000 FAN SPACER, JOHN DEERE ......................... 1 ............ R81911

4 0012110095 HEX, HEAD BOLT 4 5 0042510000 SPRING WASHER 4 6 M2303200303 ENGINE FOOT 2 7 0010312030 HEX, HEAD BOLT 6 8 0040012000 SPRING WASHER 6 9 0605000009 RUBBER SUSPENSION 2 10 0030012000 HEX, NUT 2 11 0040012000 SPRING WASHER 2

12 C0923200124 RADIATOR ....................................................... 1 ............ 232000-3240

12-1 0602011062 CAP ................................................................. 1 ............ 102600-0380

13 M9200100904 PLUG 1 14 0150000016 O RING 1 15 0016910025 HEX, HEAD BOLT 2 16 M2313300003 FAN BRACKET 1 17 0016910030 HEX, HEAD BOLT 4 18 M3310500813 RADIATOR HOSE 1 19 M3310500903 RADIATOR HOSE 1

20 0605515148 HOSE BAND ................................................... 3 ............ S/N 840001~8400030

20 0605515199 HOSE BAND ................................................... 3 ............ S/N 8400031~

21 0605515147 HOSE BAND 1

22 B6925200014 FAN MOTOR .................................................... 1 ............ VP-456SKX

23 0016910030 HEX, HEAD BOLT 8

24 0602046582 AIR CLEANER ................................................ 1 ............ FPG082527

24A 0602046365 ELEMENT, AIR CLEANER .............................. 1 ............ PB28889

25 0602040650 INDICATOR, AIR CLEANER ............................ 1 ............ RBX00-2252

26 0602040554 BAND, AIR CLEANER 1 27 0016908030 HEX, HEAD BOLT 2 28 M2373100203 HOSE, AIR CLEANER 1 29 0605515146 HOSE BAND 1 30 0605515197 HOSE BAND 1

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 63

Page 64

ENGINE & RADIATOR ASSY.

DCA-85USJ — ENGINE & RADIATOR ASSY.

PAGE 64 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 65

DCA-85USJ — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

31 0602022563 ADAPTER ........................................................ 1 ............ 10-M18 X 1.5 F80X-S

32 0602022561 90 DEGREE ELBOW 1 33 0603306590 CONNECTOR 1 34 0603300285 ROCKNUT 1 35 0605511395 VALVE 1 36 0603306395 HOSE JOINT 1 37 0602021070 CAP 1 38 0269200660 DRAIN HOSE 1 39 M9300000203 RESERVE TANK 1 40 0602010900 CAP, RESERVE TANK 1 41 M3316100303 BRACKET, RESERVE TANK 1 42 0016908020 HEX, HEAD BOLT 3 43 0199102200 HOSE 1 44 0193600700 HOSE 1 45 0193601000 HOSE 1 46 0605515106 HOSE BAND 3 47 M2326000104 BLOWBY HOSE 1 48 0605515149 HOSE BAND 1 49 M3260600104 RELAY BRACKET 1

51 0602202592 RELAY ............................................................. 1 ............ AT141011

52 0027106016 MACHINE SCREW 2 53 0030006000 HEX, NUT 2 54 M2351800004 COLLAR 4 55 0021005070 MACHINE SCREW 4 56 0040005000 SPRING WASHER 4 57 0041205000 PLAIN WASHER 4 58 0017112025 HEX, HEAD BOLT 1 59 0040512000 TOOTHED WASHER 1 60 M2325200004 HOSE CLAMPER 1 61 0017110030 HEX HEAD BOLT 1 62 0602123282 SENDER, WATER SWITCH (ENGINE SIDE) 1 63 0602122281 SENDER, OIL SWITCH (ENGINE SIDE)

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 65

Page 66

OUTPUT TERMINAL ASSY.

DCA-85USJ — OUTPUT TERMINAL ASSY.

PAGE 66 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 67

DCA-85USJ — 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 M9220100404 TIE BOLT 5 4 0039316000 HEX, NUT 10 5 0040016000 SPRING WASHER 15 6 0041416000 PLAIN WASHER 20 7 0016908035 HEX, HEAD BOLT 5 8 M3236100503 TERMINAL COVER 1 9 M3236100404 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 8 11A 0041203000 PLAIN WASHER 4 12 0030003000 HEX, NUT 8 13 0016906020 HEX, HEAD BOLT 2 14 0016906016 HEX, HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1 17 0016906020 HEX, HEAD BOLT 6

18 0601808803 CIRCUIT BREAKER ........................................ 2 ............ QOU120B1P 20A

19 0601808804 CIRCUIT BREAKER ........................................ 3 ............ QOU250B2P 50A

20 M1260700304 BREAKER FITTING COVER 1 20-1 0222100150 CUSHION RUBBER 1 21 0016906020 HEX, HEAD BOLT 2

22 0601812598 RECEPTACLE ................................................. 2 ............ GF530EM 125V 20A X 2

23 0601812538 RECEPTACLE ................................................. 3 ............ CS6369 250V 50A

24 0027104016 MACHINE SCREW 10 24A 0207004000 HEX, NUT 10 25 M2236100603 TERMINAL COVER 1 26 0010112045 HEX, HEAD BOLT 2 27 0041212000 PLAIN WASHER 2 28 M9310200004 STAY RUBBER 2 29 0030012000 HEX, NUT 2 30 0603306775 BLIND PLUG 2 31 0027104016 MACHINE SCREW 4

32 0601815194 TERMINAL ...................................................... 1 ............ 601-GP-02

33 0027104016 MACHINE SCREW 2

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 67

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 68

BATTERY ASSY.

DCA-85USJ — BATTERY ASSY.

PAGE 68 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 69

DCA-85USJ — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220187 BATTERY ........................................................ 1 ............ 627MFD

2 M9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M2346900204 BATTERY CABLE 1 6 M2346900304 BATTERY CABLE 1

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

8 0017112025 HEX, HEAD BOLT 1 9 0040520000 TOOTHED WASHER 1 10 0040512000 TOOTHED WASHER 1

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 69

Page 70

MUFFLER ASSY.

DCA-85USJ — MUFFLER ASSY.

PAGE 70 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 71

DCA-85USJ — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2330100703 MUFFLER 1 2 0017112030 HEX, HEAD BOLT 4 3 M2333000703 EXHAUST PIPE 1 4 M2333200204 GASKET 1 5 0017110040 HEX, HEAD BOLT 4 6 M3333200204 GASKET 1 7 0017110035 HEX, HEAD BOLT 4 8 M2333000603 EXHAUST PIPE 1 9 0017110050 HEX, HEAD BOLT 4 10 0602325066 CLAMP 1

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 71

Page 72

FUEL TANK ASSY.

DCA-85USJ — FUEL TANK ASSY.

PAGE 72 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 73

DCA-85USJ — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2363000902 FUEL TANK 1 1-1 0605505070 FUEL TANK CAP 1 1-2 0605501073 FUEL SENDER UNIT 1 1-3 0605516090 GASKET 1 2 M2363200404 TANK BAND 6 3 M9310500104 SUPPORTER SHEET 6 4 0016908020 HEX, HEAD BOLT 6 5 0016908040 HEX, HEAD BOLT 3 5A 0207308000 HEX, NUT 3 6 0191302040 VENT HOSE 1 7 0605515109 HOSE BAND 2 8 0191301000 SUCTION HOSE 1 9 0191301200 RETURN HOSE 1 10 0605515109 HOSE BAND 3 11 0605515189 HOSE BAND 1

12 0602042601 RETURN PIPE ................................................ 1 ............ RE67050

13 0222101000 TANK SHEET 5

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 73

Page 74

ENCLOSURE #1 ASSY.

DCA-85USJ — ENCLOSURE #1 ASSY.

PAGE 74 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 75

DCA-85USJ — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M2413001502 BASE 1 2 M2363300203 ENVIRONMENTAL TANK 1 3 0016910030 HEX, HEAD BOLT 12

4 0603306797 PLUG ............................................................... 1 ............ 1-1/2 IN.

5 M2423000702 FRONT FRAME ............................................... 1 ............ S/N 8400001 TO 8400030

5 M2423000912 FRONT FRAME ............................................... 1 ............ S/N 8400031~

5A M2493102813 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001 TO 8400030

5A M2493104103 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~

6 M2423000802 FRONT FRAME ............................................... 1 ............ S/N 8400001 TO 8400030

6 M2423001002 FRONT FRAME ............................................... 1 ............ S/N 8400031~

6A M2493102813 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001 TO 8400030

6A M2493104103 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~

7 0601851739 GROMMET ...................................................... 1 ............ S/N 8400001 TO 8400030

8 0601850100 GROMMET 1 9 0016908020 HEX, HEAD BOLT 26 10 0016910025 HEX, HEAD BOLT 6

11 M3131400203 HOSE COVER ................................................. 1 ............ S/N 8400001 TO 8400030

11A M3131400103 HOSE COVER ................................................. 1 ............ S/N 8400031~

11B M3131400004 HOSE COVER ................................................. 1 ............ S/N 8400031~

12 0016908020 HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001 TO 8400030

12 0016906020 HEX, HEAD BOLT ......................................... 13 ............ S/N 8400031~

13 M3423500104 BRACKET 1 14 0016906016 HEX, HEAD BOLT 6 15 M3423200704 DUCT COVER 2

16 0016906020 HEX, HEAD BOLT ......................................... 14 ............ S/N 8400001 TO 8400030

17 M3423200804 DUCT COVER 1 18 0016906016 HEX, HEAD BOLT 6 19 M2310300204 FAN SHROUD 1 20 M2310300304 FAN SHROUD 1 21 0016906020 HEX, HEAD BOLT 14 22 M2423300004 DISCHARGE GUIDE 1 22A M2493600004 ACOUSTIC SHEET 1 23 0016908020 HEX, HEAD BOLT 6

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 75

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 76

ENCLOSURE #1 ASSY.

DCA-85USJ — ENCLOSURE #1 ASSY.

PAGE 76 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 77

DCA-85USJ — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

24 M2423201203 COVER, FRONT FRAME ................................ 1 ............ S/N 8400001 TO 8400030

24 M2423201203 COVER, FRONT FRAME ................................ 1 ............ S/N 8400031~

24A M2493103404 ACOUSTIC SHEET 1

25 0016908020 HEX, HEAD BOLT ......................................... 27 ............ S/N 8400001 TO 8400030

25 0016908020 HEX, HEAD BOLT ......................................... 27 ............ S/N 8400031~

26 M3433000803 CENTER FRAME ............................................ 1 ............ S/N 8400001 TO 8400030

26 M3433000813 CENTER FRAME ............................................ 1 ............ S/N 8400031~

26A M3493200614 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001 TO 8400030

26A M3493201204 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~

27 0010114040 HEX, HEAD BOLT 4 27A 0030014000 HEX, NUT 4 27B 0040014000 SPRING WASHER 4 27C 0041214000 PLAIN WASHER 8 28 0010120050 HEX, HEAD BOLT 4 28A 0030020000 HEX, NUT 4 28B 0040020000 SPRING WASHER 4 28C 0041220000 PLAIN WASHER 8 29 M2463100102 ROOF PANEL 1 29A M2493501304 ACOUSTIC SHEET 1 30 M2463200102 ROOF PANEL 1 30A M2493502203 ACOUSTIC SHEET 1 31 M3463200704 BACK PLATE 2 32 0016906016 HEX, HEAD BOLT 12 33 M2463200203 DUCT 1 33A M2493502104 ACOUSTIC SHEET 1 34 0016908020 HEX, HEAD BOLT 10 35 M2463400003 DUCT COVER 1 36 0016908020 HEX, HEAD BOLT 6

37 M2423200804 OVER COVER, FRONT FRAME ..................... 1 ............ S/N 8400001 TO 8400030

37 M2423200814 OVER COVER, FRONT FRAME ..................... 1 ............ S/N 8400031~

37A M2493102604 ACOUSTIC SHEET 1

38 0016908020 HEX, HEAD BOLT ......................................... 49 ............ S/N 8400001 TO 8400030

38 0019208020 HEX, HEAD BOLT ......................................... 49 ............ S/N 840003~

39 0016910025 HEX, HEAD BOLT ........................................... 8 ............ S/N 8400001 TO 8400030

39 0019210025 HEX, HEAD BOLT ........................................... 8 ............ S/N 840003~

40 M3310600004 COVER, RADIATOR CAP 1

41 0016908020 HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001 TO 8400030

41 0019208020 HEX, HEAD BOLT ........................................... 4 ............ S/N 840003~

42 0016908020 HEX, HEAD BOLT 6 43 M2483100004 COVER, EXHAUST PIPE 1 44 0016908020 HEX, HEAD BOLT 2 45 0016908020 HEX, HEAD BOLT 1 45A 0040508000 TOOTHED WASHER 1

46 0605503062 FUEL LEAK DETECTION SWITCH ................ 1 ............ S/N 840003~

47 M1414800104 BRACKET ....................................................... 1 ............ S/N 840003~

48 0017108020 HEX HEAD BOLT ............................................ 2 ............ S/N 840003~

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 77

Page 78

ENCLOSURE #2 ASSY.

DCA-85USJ — ENCLOSURE #2 ASSY.

PAGE 78 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 79

DCA-85USJ — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3443000802 REAR FRAME ................................................. 1 ............ S/N 8400001 TO 8400020

1 M3443000812 REAR FRAME ................................................. 1 ............ S/N 8400021~

1A M3493303203 ACOUSTIC SHEET 1

2 M3443000904 DUCT ............................................................... 2 ............ S/N 8400001 TO 8400020

2 M3443000914 DUCT ............................................................... 2 ............ S/N 8400021~

2A M3493303304 ACOUSTIC SHEET 2 3 0016908020 HEX, HEAD BOLT 26 4 0016910025 HEX, HEAD BOLT 4 5 M2443300903 COVER, REAR FRAME 1 5A M2493302204 ACOUSTIC SHEET 1

6 0016908020 HEX, HEAD BOLT ......................................... 13 ............ S/N 8400001 TO 8400030

6 0019208020 HEX, HEAD BOLT ......................................... 13 ............ S/N 8400031~

7 M3443200503 DOOR, REAR FRAME 1 8 M3443600304 WINDOW PLATE 1 9 0207306000 HEX, NUT 8 9A 0041206000 PLAIN WASHER 8 10 M9113000002 DOOR HANDLE ASSY. 1 11 0021806016 MACHINE SCREW 4 11A 0030006000 HEX, NUT 4 12 M9110100204 HINGE 2 13 M9116100004 WASHER 2

14 0016908020 HEX, HEAD BOLT ........................................... 3 ............ S/N 8400001 TO 8400030

14 0019208020 HEX, HEAD BOLT ........................................... 3 ............ S/N 8400031~

15 M2453200602 SPLASHER PANEL ......................................... 1 ............ S/N 8400001 TO 8400030

15 M2453200612 SPLASHER PANEL ......................................... 1 ............ S/N 8400031~

15A M2493404604 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400001 TO 8400030

15A M2493404614 ACOUSTIC SHEET ......................................... 1 ............ S/N 8400031~

16 0016908065 HEX, HEAD BOLT ........................................... 4 ............ S/N 8400001 TO 8400030

16 0019208065 HEX, HEAD BOLT ........................................... 4 ............ S/N 8400031~

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 79

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 80

ENCLOSURE #2 ASSY.

DCA-85USJ — ENCLOSURE #2 ASSY.

PAGE 80 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 81

DCA-85USJ — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

17 0016910025 HEX, HEAD BOLT 2 18 M2453001703 SIDE DOOR 1 18A M2493404704 ACOUSTIC SHEET 1 19 M2453001803 SIDE DOOR 1 19A M2493405104 ACOUSTIC SHEET 1 20 M2453001503 SIDE DOOR 1 20A M2493404504 ACOUSTIC SHEET 1 21 M2453001603 SIDE DOOR 1 21A M2493404404 ACOUSTIC SHEET 1 22 M9113000002 DOOR HANDLE ASSY. 4 22A C9312500004 SEAL RUBBER 4 23 0021806016 MACHINE SCREW 16 23A 0030006000 HEX, NUT 16 24 M9110100804 HINGE 6 25 M9110100904 HINGE 5 26 M9116100004 WASHER 11

27 0016908020 HEX, HEAD BOLT ......................................... 26 ............ S/N 8400001 TO 8400030

27 0019208020 HEX, HEAD BOLT ......................................... 26 ............ S/N 8400031~

28 0601850097 STOPPER 8 29 0027208025 MACHINE SCREW 8 30 M9310000004 CAP 13

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 81

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 82

RUBBER SEALS ASSY.

DCA-85USJ — RUBBER SEALS ASSY.

PAGE 82 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 83

DCA-85USJ — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229200870 RUBBER SEAL 1 2 0229201130 RUBBER SEAL 1 3 0229201240 RUBBER SEAL 3 4 0228900660 RUBBER SEAL 2 5 0229201070 RUBBER SEAL 1 6 0229200125 RUBBER SEAL 4 7 0228901165 RUBBER SEAL 3 8 0228900770 RUBBER SEAL 4 9 0228901105 RUBBER SEAL 3 10 0228900565 RUBBER SEAL 1 11 0228900820 RUBBER SEAL 4 12 0228800505 RUBBER SEAL 1 13 0229201200 RUBBER SEAL 1 14 0228800635 RUBBER SEAL 1 15 0228800970 RUBBER SEAL 2 16 0228800595 RUBBER SEAL 1 17 0228100640 RUBBER SEAL 2 18 0228100370 RUBBER SEAL 2

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 83

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 84

NAME PLATE ASSY.

DCA-85USJ — NAME PLATE ASSY.

PAGE 84 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 85

DCA-85USJ — NAME PLATE ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1550000204 DECAL, NOTE ................................................................ 1 ............. M15000020

2 M1550000703 DECAL, AUXILIARY ........................................................ 1 ............. M15000070

3 M2550000503 DECAL, GENERATOR CONTROL .................................. 1 ............. M25000050

4 M2552000104 DECAL, NOTE ................................................................ 1 ............. M25200010

5 M3550001703 DECAL, ENGINE OPERATING ....................................... 1 .............M35000170

......................................................................................................... S/N 8400001~8400030

5 M3550002003 DECAL, ENGINE OPERATING ....................................... 1 ............. S/N 840031~

6 M3550001803 DECAL, OPERATING PROCEDURES ............................ 1 ............. M35000180A

7 M9500000004 DECAL, OIL DRAIN PLUG .............................................. 1 ............. M90000000

8 M9500100004 DECAL, WATER .............................................................. 1 ............. M90010000

......................................................................................................... S/N 8400001~8400030

8 M9500100004 DECAL, WATER .............................................................. 1 ............. M90010000

......................................................................................................... S/N 840031~

9 M9500300004 DECAL, NEGATIVE ........................................................ 1 ............. M90030000

10 M9500300104 DECAL, POSITIVE ......................................................... 1 ............. M90030010

11 M9500500004 DECAL, DIESEL FUEL ................................................... 1 .............M90050000

12 M9503000004 DECAL, WARNING MOVING PARTS .............................. 2 ............. M90300000

13 M9503000103 DECAL, WATER - OIL CHECK ........................................ 1 ............. M90300010

14 M9503100004 DECAL, WARNING HOT COOLANT ............................... 1 ............. M90310000

......................................................................................................... S/N 8400001~8400030

14 M9503100004 DECAL, WARNING HOT COOLANT ............................... 1 ............. M90310000

......................................................................................................... S/N 840031~

15 M9503200004 DECAL, WARNING ENGINE EXHAUST ......................... 1 ............. M90320000

16 M9510000004 DECAL, FLUID DRAIN .................................................... 1 .............M91000000

17 M9510100004 DECAL, CAUTION HOT PARTS ...................................... 1 ............. M91010000

18 M9510100403 DECAL, CAUTION .......................................................... 1 ............. M91010040

19 M9520000004 DECAL, GROUND ........................................................... 1 .............M92000000

20 M9520000104 DECAL, AMMETER CHANGE-OVER SW. ..................... 1 ............. M92000010

21 M9520000204 DECAL, VOLTMETER CHANGE-OVER SW. ................... 1 ............. M92000020

22 M9520000504 DECAL, START CONTACT ............................................. 1 ............. M92000050

23 M9520100004 DECAL, WARNING ELECTRIC SHOCK HAZARD .......... 2 ............. M92010000

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 85

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

Page 86

NAME PLATE ASSY.

DCA-85USJ — NAME PLATE ASSY.

PAGE 86 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 87

DCA-85USJ — NAME PLATE ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

24 M9520100204 DECAL, CAUTION .................................................... 1 ..............M92010020A

25 M9520100304 DECAL, SAFETY INSTRUCTIONS .......................... 1 .............. M92010030

26 M9520100404 DECAL, DANGER HIGH VOLTAGE .......................... 1 .............. M92010040

27 M9520100503 DECAL, WARNING ................................................... 1 ..............M92010050

28 M9520100603 DECAL, CAUTION .................................................... 2 ..............M92010060

29 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE ......... 1 .............. M92020000

30 0021106016 MACHINE SCREW ................................................... 4 ..............S/N 8400031~

31 M9512200004 DECAL, MQ.............................................................. 1 .............. M91220000

32 M9510200304 DECAL, MQ POWER 3 33 M3560102004 STRIPE 2 34 M2560100603 STRIPE, WHISPERWATT 2 35 M3560102204 STRIPE 2 36 M2560100703 STRIPE, 85 1 37 M2560100803 STRIPE, 85 1 38 M3560102504 STRIPE 2

39 M9510100304 DECAL, ENVIRONMENTAL WARNING .................... 1 .............. M91010030

................................................................................................... S/N 8400031~

40 0600500092 PLATE, MQ POWER ................................................ 1 .............. S/N 8400031~

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 87

Page 88

Effective: October 1, 2002

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 shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

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

RETURNED GOODS POLICY

Return shipments will be 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 Retur n Material Authorization, 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 parts must be retur ned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

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

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

a. Obsolete parts. (If an item is in the

price book and shows 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 par ts) 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.

material received that is not acceptable.

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

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.

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 $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

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 manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty 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. Apar t 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 88 — DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04)

Page 89

NOTE PAGE

DCA-85USJ — OPERATION AND PARTS MANUAL — REV. #0 (09/17/04) — PAGE 89

Page 90

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-mail: mqpower@multiquip.com Internet: www.mqpower.com

MULTIQUIP Power Ultra-Silent DCA-85USJ Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual