ULTRA-SILENTTM SERIES
MODEL DCA-70USJ
GENERATOR
PARTS LIST NO. M2870400114
Revision #0 (09/16/04)
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 3
TABLE OF CONTENTS
MQ POWER DCA-70USJ COMPONENT DRAWINGS
DRAWINGS
ULTRA-SILENT GENERA
ULTRA-SILENT TOR
GENERATOR Explanation of Code in Remarks Column ....................... 54
Suggested Spare Parts .................................................. 55
California Proposition 65 Warning ..................................... 2
Generator Assembly .................................................. 56-57
Here's How To Get Help .................................................... 3
Control Box Assembly ............................................... 58-61
Table Of Contents ............................................................. 4
Engine & Radiator Assembly ..................................... 62-65
Parts Ordering Procedures ............................................... 5
Output Terminal Assembly ......................................... 66-67
Specifications ................................................................... 6
Battery Assembly ...................................................... 68-69
Dimensions (Top, Side, Front) ........................................... 7
Muffler Assembly ...................................................... 70-71
Safety Message Alert Symbols .................................... 8-9
Fuel Tank Assembly .................................................. 72-73
Rules for Safe Operation ........................................... 10-13
Enclosure #1 Assembly ............................................ 74-77
Generator Decals ....................................................... 14-15
Enclosure #2 Assembly ............................................ 78-79
Installation ................................................................. 16-17
Rubber Seals Assembly ............................................ 80-81
General Information ........................................................ 18
Nameplate and Decals .............................................. 82-83
Major Components ......................................................... 19
Generator Control Panel ................................................. 20
Terms and Condition of Sale Parts ............................ 84
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 Specification and part
Generator Start-up Procedure (Auto Mode) .................... 39 NOTE number are subject to
change without notice.
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
Heres how to get help... Place Your Parts Order Via Web or Fax
Please have the model and serial number
For Even More Savings!
on hand when calling. (Domestic USA Dealers Only)
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave. 800-421-1244 Extra Discounts!
Carson, CA 90746 FAX: 310-632-2656 All parts orders which include complete part numbers and
Email: mqpower@multiquip.com are received by our automated web parts order system, or
Internet: www.mqpower.com by fax qualify for the following extra discounts:
PARTS DEPARTMENT Ordered Standard Stock orders
800-427-1244 FAX: 800-672-7877 via orders ($750 list and above)
310-537-3700 FAX: 310-637-3284 Fax 3% 10%
SERVICE DEPARTMENT Web 5% 10%
800-835-2551 FAX: 310-638-8046 Special freight allowances
310-537-3700
TECHNICAL ASSISTANCE when you order 10 or more
800-835-2551 FAX: 310-638-8046 line items via Web or Fax!**
WARRANTY DEPARTMENT FedEx Ground Service at no charge for freight
800-835-2551, EXT. 279 FAX: 310-638-8046 No other allowances on freight shipped by any other carrier.
310-537-3700, EXT. 279
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
MQPOWER
A Division of Multiquip Inc.
Direct TOLL-FREE access
POST OFFICE BOX 6254
CARSON, CA 90749
to our Parts Department:
310-537-3700 800-421-1244 Toll-free nationwide 800-427-1244
FAX: 310-632-2656
E-MAIL: mqpower@multiquip.com Toll-free FAX 800-6-PARTS-7 1(800/672-7877)
INTERNET: www.mqpower.com
Phase 3 Single
Voltage 24 0 V o r 4 8 0 V 240/120V
Frequency 60 Hz
Speed 1800 r pm
Voltage 120 V
Coolant Capacity 3.7 gal. (14 liters) plus 2 quar ts in retaining tank
5.0 gal. (18.9 L)/hr at full load 3.5 gal. (13.4 L)/hr at 3/4 load
Fuel Consumption
2.4 gal. (8.8 L)/hr at 1/2 load 1.6 gal. (5.9 L)/hr at 1/4 load
Figure 1. Dimensions 1
DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 7
DCA85USJ SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS
Safety precautions should be followed at all times when Potential hazards associated with the operation of this
operating this equipment. Failure to read and understand the equipment will be referenced with "Hazard Symbols" which
Safety Messages and Operating Instructions could result in appear throughout this manual, and will be referenced in
injury to yourself and others. conjunction with Safety "Message Alert Symbols".
You COULD be KILLED or SERIOUSLY injured if Engine components can generate extreme
you do not follow directions. heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
CAUTION operate the engine with heat shields or heat
guards removed.
You CAN be injured if you do not follow directions
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 9
DCA-70USJ RULES FOR SAFE OPERATION
ALWAYS check the machine for loosened threads or bolts
DANGER - READ THIS MANUAL!
before starting.
Failure to follow instructions in this manual may lead to NEVER operate the generator in an explosive atmosphere
serious injury or even DEATH! This equipment is to be or near combustible materials. An explosion or fire could
operated by trained and qualified personnel only! This result causing severe bodily harm or even death.
equipment is for industrial use only.
NEVER touch the hot exhaust manifold, muffler
The following safety guidelines should always be used when or cylinder. Allow these parts to cool before
operating the DCA-70USJ Generator: servicing engine or generator.
General Safety: High Temperatures Allow the engine
to cool before performing service and
DO NOT operate or service this
maintenance functions. Contact with
equipment before reading this entire
hot! components can cause serious
manual.
burns.
The operator MUST BE familiar with proper safety
The engine of this generator requires an adequate free
precautions and operations techniques before using
flow of cooling air. NEVER operate the generator in any
generator.
enclosed or narrow area where free flow of the air is
This equipment should not be operated by persons under restricted. If the air flow is
18 years of age. restricted it will cause serious
NEVER operate this equipment without proper protective damage to the generator or
clothing, shatterproof glasses, steel-toed boots and other engine and may cause injury
protective devices required by the job. to people. The generator
engine gives off DEADLY
carbon monoxide gas.
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
NEVER operate this equipment when not NEVER run engine without air filter. Severe engine damage
feeling well due to fatigue, illness or taking may occur.
medicine.
DO NOT leave the generator running in the manual mode
NEVER operate this equipment under the influence or unattended.
drugs or alcohol.
Refer to the John Deere Engine Owner's Manual for
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.
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.
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 11
DCA-70USJ RULES FOR SAFE OPERATION
Maintenance Safety Battery Safety
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:
can cause severe injury or even death through physical The battery contains acids that can
contact with live circuits. Turn all circuit breakers OFF cause injury to the eyes and skin. To
before performing maintenance on the generator. avoid eye irritation, always wear safety
NEVER lubricate components or attempt service on a glasses.
running machine. Use well insulated gloves when picking up the battery.
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator. DANGER - EXPLOSION HAZARDS
Follow all Battery Safety Guidelines listed in this manual The risk of an explosion exists when performing service
when handleing or servicing the generator. on the battery. To avoid severe injury or DEATH:
ALWAYS allow the machine a proper amount of time to DO NOT drop the battery. There
cool before servicing. is the possibility of risk that the
Keep the machinery in proper running condition. battery may explode.
Fix damage to the machine immediately and always DO NOT expose the battery to
replace broken parts. open flames, sparks, cigarettes
ALWAYS service air cleaner frequently to prevent engine etc. The battery contains combustible gases and liquids.
malfunction. If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
WARNING - BURN HAZARDS
ALWAYS keep the battery charged. If the battery is not
To prevent burns, DO NOT touch or open any of the below charged a buildup of combustible gas will occur.
mentioned components while the engine is
ALWAYS keep battery charging and cables in good working
running or immediately after operations. condition. Repair or replace all worn cables.
Always allow sufficient time for the engine
and generator to cool before performing ALWAYS recharge the battery in an vented air
maintenance. environment, to avoid risk of a dangerous concentration
of combustible gases.
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water In case the battery liquid (dilute sulfuric acid) comes in
to gush out of the radiator, causing severe scalding to contact with clothing or skin, rinse skin or clothing
any persons in the general area of the generator. immediately with plenty of water.
Coolant Drain Plug - Removing the coolant drain plug In case the battery liquid (dilute sulfuric acid) comes in
while the engine is hot will result in hot coolant gushing contact with your EYES, rinse eyes immediately with
out of the coolant drain plug, therefore causing severe plenty of water and contact the nearest doctor or hospital
scalding to any persons in the general area of the to seek medical attention.
generator.
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.
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 13
DCA-70USJ GENERATOR DECALS
The DCA-70USJ 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.
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DCA-70USJ GENERAL INFORMATION
DCA-70USJ Series Familiarization Open Delta Excitation System
Generator The DCA-70USJ generator is equipped with the state of the
The MQ Power Model DCA-70USJ is a 56 kW generator art "Open-Delta" excitation system. The open delta system
(Figure 5) that is designed as a high quality portable (requires consist of an electrically independent winding wound among
stationary windings of the AC output section.
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other industrial There are four connections of the open delta A, B, C and D.
and construction machinery. During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
Engine Operating Panel and C to D. These three phases of the voltage input to the
The Engine Operating Panel is provided with the following: voltage regulator are then rectified and are the excitation
Tachometer current for the exciter section.
Water Temperature Gauge When a heavy load, such as a motor starting or a short
Oil Pressure Gauge circuit occurs, the automatic voltage regulator (AVR)
Charging Ammeter Gauge switches the configuration of the open delta to the series
Fuel Level Gauge connection of B to C. This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
Pre-heat Lamp
section and thus better voltage response during the
Panel Light/Panel Light Switch application of heavy loads.
Auto ON/OFF Engine Controller (MPEC)
Fuel Leak Detected Alarm Lamp
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Generator Control Panel
The open-delta design provides virtually unlimited excitation
The Generator Control Panel is provided with the following: current, offering maximum motor starting capabilities. The
Frequency Meter (Hz) excitation does not have a "fixed ceiling" and responds
AC Ammeter (Amps) according the demands of the required load.
AC Voltmeter (Volts) Engine
Ammeter Change-Over Switch The DCA-70USJ is powered by a 4 cycle, water cooled,
Voltmeter Change-Over Switch direct injection, turbocharged John Deere Model 4045TF275
Voltage Regulator Diesel Engine. This engine is designed to meet every
3-Pole, 175 amp Main Circuit Breaker performance requirement for the generator. Reference Table
Control Box (located behind the Gen. Control Panel) 1 for engine specifications.
Automatic Voltage Regulator In keeping with MQ Power's policy of constantly improving
Current Transformer its products, the specifications quoted herein are subject to
Over-Current Relay change without prior notice.
Voltage Rectifer Electric Governor System
Starter Relay
The electric governor system controls the RPMs of the
Engine Controller (Computer Controlled) engine. When the engine demand increases or decreases,
Voltage Selector Switch the governor system regulates the frequency variation to
Output Terminal Panel .25%.
The Output Terminal Panel is provided with the following: Extension Cables
Three 120/240V output receptacles (CS-6369), 50A When electric power is to be provided to various tools or
Three auxilliary circuit breakers, 50A loads at some distance from the generator, extension cords
Two 120V output receptacles (GFCI), 20A are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
Two GFCI circuit breakers, 20A
between the generator and point of use (load) is held to a
Five output terminal lugs (3 power) minimum. Use the cable selection chart (Table 5) as a guide
Battery Charger (Optional) for selecting proper extension cable size.
Water Heater (Optional)
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 19
NOTE PAGE
The definitions below describe the controls and functions of Located behind the generator control panel is the Generator
the DCA-70USJ Generator Control Panel (Figure 6). Control Box. This box contains some of the necessary
1. Main Circuit Breaker This three-pole, 175A main electronic components required to make the generator
breaker is provided to protect the the U,V, and W Output function.
Terminal Lugs from overload. The Control Box is equipped with the following major
2. Frequency Meter Indicates the output frequency in components:
hertz (Hz). Normally 60 Hz. Over-Current Relay
Voltage Rectifer (AVR)
3. AC Ammeter Indicates the amount of current the load Starter Relay
is drawing from the generator per leg selected by the Current Transformer
ammeter phase-selector switch. Voltage Selector Switch
4. Ammeter Change-Over Switch This switch allows
the AC ammeter to indicate the current flowing to the Remember the overcurrent
load connected to any phase of the output terminals, or NOTE relay monitors the current
to be switched off. This switch does not effect the flowing from the U,V, and W
generator output in any fashion, it is for current reading Output Terminal Lugs to the
only. load.
5. AC Voltmeter Indicates the output voltage present at In the event of a short circuit or over current condition, it will
the U,V, and W Output Terminal Lugs. automatically trip the main breaker.
6. Voltmeter Change-Over Switch This switch allows To restore power to the Output Terminal Panel, press the
the AC voltmeter to indicate phase to phase voltage reset button on the overcurrent relay and place the main
between any two phases of the output terminals or to circuit breaker in the closed position (ON).
be switched off.
7. Voltage Regulator Control Allows 15% manual
adjustment of the generators output voltage.
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DCA-70USJ ENGINE OPERATING PANEL
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DCA-70USJ OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel Output Terminal Familiarization
The Output Terminal Panel (Figure 8) shown below is located The Output Terminal Panel (Figure 8) is provided with the
on the right-hand side (left from control panel) of the generator. following:
Lift up on the cover to gain access to receptacles and terminal Three (3) 120/240V output receptacles @ 50 amp
lugs.
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
NOTE Terminal legs O and Ground
are considered bonded grounds. Two (2) GFCI Circuit Breakers @ 20 amps
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 27
DCA-70USJ GENERATOR OUTPUTS
Voltage Selector Switch Generator Amperage
The voltage selector switch (Figure 16) is located above Table 7 describes the generators current output capability
the output terminal panels Hard Wire Hook-up Panel. It for both 1-phase and 3 phase applications.
has been provided for ease of voltage selection.
Table 7. Generator Ampere Ratings
DCA-8USJ kW kVA 120V 208V 240V 480V
Single Phase 40 N/A 166.7A x 2 N/A 1 6 6 .7 A N/A
Three Phase* 56 70 N/A 155A 134A 67A
* Power Factor = 0.8
Single Phase
120V 127V 139V 240V 254V 277V
(Switchable)
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 31
DCA-70USJ PRE-SETUP
Circuit Breakers Fuel Check
To protect the generator from an overload, a 3-pole, 175 amp,
main circuit breaker is provided to protect the U,V, and W DANGER - EXPLOSION/FIRE HAZARDS
Output Terminals from overload. In addition two single-pole, Fuel spillage on a hot engine can cause a fire or explosion.
20 amp GFCI circuit breakers are provided to protect the If fuel spillage occurs, wipe up the spilled fuel completely
GFCI receptacles from overload. Three 50 amp load circuit to prevent fire hazards. NEVER smoke around or near the
breakers have also been provided to protect the auxiliary 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 Refilling the Fuel System
selection of engine oil.
CAUTION - REFUELING THE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
F C OIL: SAE
122 50
104 40
10W/40
86 30
20W40
10W40
68 20
30
15W30
50 10
10W
10W30
-14 -10
ARCTIC OIL
-4 -20
-22 -30
-40 -40
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).
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Figure 36. Fuel Expansion
Reserve Tank 2 Quar ts (1.9 liters) Figure 37. Fan Belt Tension
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DCA-70USJ GENERATOR START-UP PROCEDURE (MANUAL)
Before Starting 4. Close all engine enclosure doors (Figure 40).
NEVER! manually start the engine with the main, GFCI Figure 40. Engine Enclosure Doors
or auxiliary circuit breakers in the ON (closed) position.
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DCA-70USJ GENERATOR START-UP PROCEDURE (MANUAL)
12. The engine oil pressure gauge 15. Place the main, GFCI, and aux. circuit breakers in the
(Figure 49) will indicate the oil ON position (Figure 52).
pressure (kg/ cm2) of the engine.
Under normal operating conditions
the oil pressure is approximately
35~65 PSI.
Figure 49. Oil Pressure Gauge
CAUTION - BACKUP GENERATOR USE 3. Continue to follow the steps outlined in the Manual Start-
up procedure (start at step 9).
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.
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 39
DCA-70USJ GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
WARNING - SHUTTING DOWN THE GENERATOR
1. To shut-down the engine in the event of an emergency,
NEVER stop the engine suddenly except in an emergency. switch the MAIN, GFCI and LOAD (Figure 39) circuit
DO NOT use the emergency stop switch a as method of breakers to OFF position.
shutting down the generator. This switch is ONLY to be
2. Place the MPEC Control Switch switch (Figure 55) to
used in the event of an emergency.
the OFF/RESET position.
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 MPEC Control Switch (Figure 55) to the
OFF/RESET position.
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DCA-70USJ TRAILER MAINTENANCE
Trailer Maintenance 8. Tire Size - Indicates the diameter of the tire in inches
This section is intended to provide the user with generic (10,12,14, etc.), and the width in millimeters
trailer service and maintenance information. The service and (175,185,205, etc.). The tire diameter must match the
maintenance guidelines referenced in this section refer to a diameter of the tire rim.
wide range of trailers. 9. Tire Ply - The tire ply (layers) number is rated in letters;
Remember periodic inspection of the trailer will ensure safe 2-ply,4-ply,6-ply, etc.
towing of the generator and will prevent personal injury and 10. Wheel Hub - The wheel hub is connected to the trailers
damage to the equipment. axle.
The definitions below describe some of the major components 11. Tire Rim - Tires mounted on a tire rim. The tire rim must
of a typical trailer that would be used with the DCA-70USJ match the size of the tire.
Ultra-Silent Generator.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
1. Fuel Cell - Provides an adequate amount of fuel for the Always use a torque wrench to tighten down the lug
equipment in use. Fuel cells must be empty when trans- nuts. See Table 17 and Figure 59 for lug nut tightening
porting equipment. and sequence.
2. Braking System - System employed in stopping the 13. Axle - Indicates the maximum weight the axle can sup-
trailer. Typical braking systems are electric, surge, hy- port in pounds, and the diameter of the axle expressed
draulic, hydraulic-surge and air. in inches. Please note that some trailers have a double
3. GVWR- Gross Vehicle Weight Rating (GVWR) is the axle. This will be shown as 2-6000 lbs., meaning two
maximum number of pounds the trailer can carry, in- axles with a total weight capacity of 6000 pounds.
cluding the fuel cell (empty). 14. Suspension - Protects the trailer chassis from shocks
4. Frame Length - Measurement is from the ball hitch to transmitted through the wheels. Types of suspension
the rear bumper (reflector). used are leaf, Q-flex, and air ride.
5. Frame Width - Measurement is from fender to fender 15. Electrical - Electrical connectors (looms) are provided
6. Jack Stand - Trailer support device with maximum pound with the trailer so the brake lights and turn signals can
requirement from the tongue of the trailer. be connected to the towing vehicle.
7. Coupler - Type of hitch used on the trailer for towing. 16. Application - Indicates which units can be employed
on a particular trailer.
TABLE 15. TIRE WEAR TROUBLESHOOTING SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
SHACKLE BOLT
CAUSE SOLUTION LOCKING NUTS OR COTTER PINS ARE PROVIDED
WEAR PATTERN SPRING EYE BOLT
Adjust pressure to TO RETAIN NUT-BOLT ASSEMBLY.
Center Wear Over Inflation. particular load per tire
manufacturer. SHOULDER TYPE
Adjust pressure to MIN-30 MAX-50
SHACKLE BOLT
Edge Wear Under Inflation. particular load per tire
manufacturer.
Make sure load does
Loss of camber
Side Wear not exceed axle rating.
or overloading.
Align wheels.
Toe Wear Incorrect toe-in. Align wheels.
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DCA-70USJ TRAILER WIRING DIAGRAM
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Figure 61. Generator Wiring Diagram
Defective Exciter Field? Check for 17.3 ohms across J & K on CN1
Low Voltage Output Is engine speed correct? Turn engine throttle lever to "High".
High Voltage Output Is wiring connections loose? Check wiring and repair.
Circuit Breaker Tripped Shor t Circuit in load? Check load and repair.
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DCA-70USJ 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.
Low oil pressure light is Oil pressure sending unit failure? Replace oil pressure sending unit.
on. Time delay malfuntion in Controller? Refer to dealer.
High coolant temper ture Exhaust leaking? Replace/repair gaskets or faulty par t.
lig h t i s o n . Generator being overloaded? Check/reduce load.
Loss of MPU light(s) or Magnetic pick up out of adjustment? Adjust magnetic pick up.
on. Magnetic pick up dir ty? Clean magnetic pick up.
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DCA-70USJ OPERATION AND PARTS MANUAL REV. #0 (09/16/04) PAGE 53
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.
*
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DCA-70USJ GENERATOR ASSY.
GENERATOR ASSY.
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DCA-70USJ CONTROL BOX ASSY.
CONTROL BOX ASSY.
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DCA-70USJ ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
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DCA-70USJ ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
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DCA-70USJ OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
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DCA-70USJ MUFFLER ASSY.
MUFFLER ASSY.
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DCA-70USJ FUEL TANK ASSY.
FUEL TANK ASSY.
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DCA-70USJ ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
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DCA-70USJ ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
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DCA-70USJ NAME PLATE ASSY.
NAME PLATE ASSY.
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Effective: October 1, 2002 TERMS AND CONDITIONS OF SALE PARTS
PAYMENT TERMS 5. Parts must be in new and resalable con- for price declines and added charges for price
Terms of payment for parts are net 10 days. dition, in the original Multiquip package (if increases will not be made for stock on hand at
any), and with Multiquip part numbers the time of any price change.
FREIGHT POLICY clearly marked. Multiquip reserves the right to quote and sell
All parts orders will be shipped collect or 6. The following items are not returnable: direct to Government agencies, and to Original
prepaid with the charges added to the invoice. Equipment Manufacturer accounts who use
All shipments are F.O.B. point of origin. a. Obsolete parts. (If an item is in the
price book and shows as being our products as integral parts of their own
Multiquips responsibility ceases when a signed products.
manifest has been obtained from the carrier, replaced by another item, it is
and any claim for shortage or damage must be obsolete.) SPECIAL EXPEDITING SERVICE
settled between the consignee and the carrier. b. Any parts with a limited shelf life A $35.00 surcharge will be added to the invoice
MINIMUM ORDER (such as gaskets, seals, O rings, for special handling including bus shipments,
and other rubber parts) that were pur- insured parcel post or in cases where Multiquip
The minimum charge for orders from Multiquip chased more than six months prior to must personally deliver the parts to the carrier.
is $15.00 net. Customers will be asked for the return date.
instructions regarding handling of orders not LIMITATIONS OF SELLERS LIABILITY
meeting this requirement. c. Any line item with an extended dealer Multiquip shall not be liable here under for
net price of less than $5.00. damages in excess of the purchase price of the
RETURNED GOODS POLICY
d. Special order items. item with respect to which damages are claimed,
Return shipments will be accepted and credit and in no event shall Multiquip be liable for loss
will be allowed, subject to the following provi- e. Electrical components.
of profit or good will or for any other special,
sions: f. Paint, chemicals, and lubricants. consequential or incidental damages.
1. A Returned Material Authorization must g. Decals and paper products. LIMITATION OFWARRANTIES
be approved by Multiquip prior to ship- h. Items purchased in kits.
ment. No warranties, express or implied, are made in
7. The sender will be notified of any connection with the sale of parts or trade
2. To obtain a Return Material Authorization, material received that is not acceptable. accessories nor as to any engine not manufac-
a list must be provided to Multiquip Parts tured by Multiquip. Such warranties made in
Sales that defines item numbers, quanti- 8. Such material will be held for five
working days from notification, pending connection with the sale of new, complete units
ties, and descriptions of the items to be are made exclusively by a statement of war-
returned. instructions. If a reply is not received
within five days, the material will be re- ranty packaged with such units, and Multiquip
a. The parts numbers and descriptions turned to the sender at his expense. neither assumes not authorizes any person to
must match the current parts price assume for it any other obligation or liability
list. 9. Credit on returned parts will be issued at whatever in connection with the sale of its
dealer net price at time of the original products. Apart from such written statement of
b. The list must be typed or computer purchase, less a 15% restocking charge.
generated. warranty, there are no warranties, express,
10. In cases where an item is accepted, for implied or statutory, which extend beyond the
c. The list must state the reason(s) for which the original purchase document description of the products on the face hereof.
the return. can not be determined, the price will be
d. The list must reference the sales based on the list price that was effective
order(s) or invoice(s) under which the twelve months prior to the RMA date.
items were originally purchased. 11. Credit issued will be applied to future
e. The list must include the name and purchases only.
phone number of the person request- PRICING AND REBATES
ing the RMA.
Prices are subject to change without prior
3. A copy of the Return Material Authoriza- notice. Price changes are effective on a spe-
tion must accompany the return shipment. cific date and all orders received on or after that
4. Freight is at the senders expense. All date will be billed at the revised price. Rebates
parts must be returned freight prepaid to
Multiquips designated receiving point.
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL