Operation and parts Manual ® Whisperwatt™ Series MODEL DCA70SSJU4i 60Hz GENERATOR (JOHN DEERE 4045HFG92 DIESEL ENGINE) PARTS LIST NO. M2871300004 Revision #2 (04/09/14) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
proposition 65 warning Diesel engine exhaust and some of page 2 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip Inc. at 1-800-421-1244. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Table of Contents DCA70SSJU4i 60 Hz Generator Proposition 65 Warning............................................ 2 Reporting Safety Defects.......................................... 3 Table Of Contents..................................................... 4 Safety Information............................................... 6-11 Generator/Engine Specifications............................ 12 Generator Dimensions............................................ 13 Trailer Dimensions/Specifications..................
notes dca70SSJU4i 60 hz generator• operation manual — rev.
Safety Information Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others. Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.
Safety Information general saFetY caution never operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations. never operate this equipment when not feeling well due to fatigue, illness or when under medication. never operate this equipment under the influence of drugs or alcohol.
Safety Information engine saFetY daNgeR The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. The engine of this equipment requires an adequate free flow of cooling air. never operate this equipment in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine.
Safety Information Fuel saFetY daNgeR dO NOT start the engine near spilled fuel or combustible fluids. Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited. 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.
Safety Information electrical saFetY daNgeR dO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn. The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.
Safety Information If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing immediately with plenty of water. emissions inFormation If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.
generator/engine Specifications Model Type Table 1. Generator Specifications DCA70SSJU4i Revolving field, self ventilated, open protected type synchronous generator Star with Neutral Zigzag 3Ø 3Ø 61.
generator Dimensions Figure 1. Dimensions Table 3. Generator Dimensions Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) A 39.25 (997) E 39.25 (997) B 32.80 (883) F 105.12 (2,670) C 39.25 (997) G 68.30 (1,735) D 32.28 (820) H 37.40 (950) dca70SSJU4i 60 hz generator• operation manual — rev.
trailer Dimensions/specifications TOP VIEW B C D A SIDE VIEW F E G Figure 2. Trailer Dimensions Table 4. Trailer Dimensions Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) A 169.4 (4,938) E 24.2 (615) B 47.5 (1,207) F 20.2 (513) C 60 (1,524) G 20.35 (517) D 72.5 (1,842) Table 5. TRLR70USH Trailer Specifications Gross Vehicle Weight Rating (GVWR) 7,000 lbs. (3,175 kg) Gross Axle Weight Rating (GAWR) Each 3,500 lbs. (1,588 kg) Actuator Rating 8,000 lbs.
notes dca70SSJU4i 60 hz generator• operation manual — rev.
Installation Figure 3. Typical Generator Grounding Application page 16 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
Installation Outdoor Installation Generator Grounding 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. To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground (Figure 3).
General Information Generator Open Delta Excitation System This generator (Figure 4) 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. Each generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.
generator Major Components Figure 4. GeneratorMajor Components Table 6. Generator Major Components ITEM NO. DESCRIPTION 1 Muffler Assembly 2 Enclosure Assembly 3 Voltage Selector Switch Assembly 4 Generator Assembly 5 Output Terminal Assembly 6 Battery Assembly 7 Engine Assembly 8 Fuel Tank Assembly 9 Circuit Breaker Assembly 10 Auto Start/Stop Controller Assembly 11 Gauge Unit Assembly 12 Generator Control Panel Assembly dca70SSJU4i 60 hz generator• operation manual — rev.
trailer Major Components 11 1 2 3 10 9 5 8 7 6 4 Figure 5. Trailer Major Components Figure 5 shows the location of the trailer components and the 600 VAC option. The function of each component is described below: 5. Side Reflectors — There are two amber reflectors located on the side of the trailer. These reflectors provide better visibility in dark conditions. 1. Auto-Transformer (Option) — Voltage converter transformer. Converts the generator's 3Ø, 480 output voltage to 3Ø, 600 VAC. 6.
engine control unit (ecu) 1 25 ECU 50 75 140 PSI 0 100 180 18 12 220 24 °F 100 VOLTS 260 6 30 DECREASE INCREASE OIL PRESS Series 800 Controller Engine Started Shutdown A Pre-Alarm B C D WATER TEMP BATTERY ½ 120 150 180 60 RPMX10 E F FUEL 0 V 210 SPEED U W OFF ECU V-W Series 800 Controller Engine Started W-U U-V Shutdown OFF Pre-Alarm Alarm Screen Acknowledge Change E Option F G Program Exit Screen Alarm Acknowledge Change Option Program/ Exit H Figure 6.
ENGINE/Generator Control Panel 4 1 2 25 50 3 75 50 A 75 140 B 180 C 18 12 220 0 100 24 °F VOLTS 100 260 6 30 WATER TEMP BATTERY 11 120 PSI 100 °F 100 150 180 60 VOLTS RPMX10 6 260 DECREASE INCREASE OIL PRESS 24 ½ 0 8 18 12 220 PSI 25 5 180 140 E 30 F FUEL 0 V 210 SPEED U OIL PRESS WATER TEMP D BATTERY E ½ 120 6 180 ECU V-W Series 800 Controller Engine Started RPMX10 F 9 150 60 °F E W OFF 0 210 W-U U-V 7 Shutdown 10 OFF Pre-Alarm
OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization 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 lugs. The “Output Terminal Panel ” (Figure 8) is provided with the following: Three 240/139V output receptacles @ 50 amps Three Aux.
OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board configuration. 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.
OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay Loads can be connected to the generator by various methods, output terminal lugs, camlocks or the convenience receptacles (Figure 13). Make sure to read the operation manual before attempting to connect a load to the generator. An 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.
Load Application Single Phase Load Three Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment. When calculating the power requirements for 3-phase power use the following equation: Generally, the wattage listed on the nameplate of the equipment is its rated output.
GENERATOR OUTPUTS Generator Output Voltages Maximum Amps 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 9 (see below) will require a fine adjustment using the voltage regulator (VR) control knob located on the control panel. Table 10 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed. Table 10.
GENERATOR OUTPUTS/gauge reading how to Read the ac ammeter and ac voltage gauges The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches. Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.
OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob. Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage. 3Ø-240V UVWO Terminal Output Voltages 1.
OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 25. 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 27. Figure 25. Voltage Selector Switch 3Ø-480/277V Position Figure 27. Voltage Selector Switch 1Ø-240/120V Position 2. Connect the load wires to the UVWO terminals as shown in Figure 26. 2.
600 VAC CONNECTIONS 3Ø-600V Auto-Transformer 3Ø, 600 VAC can be achieved via the auto-transformer module. This module provides the necessary electronics to convert the 3Ø, 480 VAC inut voltage to a 3Ø, 600 VAC output voltage. The 3Ø, 600 VAC ouput voltage cannot be achieved unless the voltage selector switch (Figure 29) is placed in the 3Ø, 480/277 position. 3. After drilling, make sure all shavings and debris have been removed from the enclosure. 4.
inspection/SETUP Circuit Breakers To protect the generator from an overload, a 3-pole, 200 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.
inspection/SETUP Refueling Procedure: 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 36). WARNING 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 34).
inspection/SETUP 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 14 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings. Table 14. Coolant Capacity Engine and Radiator 5.92 gal (22.
inspection/SETUP Battery Cable Installation Alternator ALWAYS be sure the battery cables (Figure 39) 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. 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.
GENERATOR START-UP PROCEDURE (MANUAL mode) 1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 40) in the OFF position prior to starting the engine. NOTICE If engine fails to start in a specified number attempts, the shutdown lamp will illuminate and the Auto-Off/ Reset Switch must be place in the Off/Reset position before the engine can be restarted. NOTICE Figure 40. Main, Aux. and GFCI Circuit Breakers (OFF) 2.
GENERATOR START-UP PROCEDURE (manual mode) 6. The ammeter (Figure 46) 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. 10. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 50). Figure 46. Ammeter (No Load) Figure 50. Main, Aux. and GFCI Circuit Breakers (ON) 7. The engine oil pressure gauge (Figure 47) will indicate the oil pressure of the engine.
GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING AUTO MODE DANGER Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch. When starting generator in AUTO mode use the “Manual Start-up” procedure except where noted (see below). 1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure. 2.
GENERATOR SHUT-DOWN PROCEDURES WARNING NEVER stop the engine suddenly except in an emergency. 6. Place the 70 amp circuit breaker switch (Figure 56) on the 600 VAC control box enclosure to the OFF position. OFF Normal Shutdown Procedure To shutdown the generator, use the following procedure: 1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 54 to the OFF position. Figure 56. Circuit Breaker OFF (600 VAC) 7.
Maintenance 10 Hrs DAILY Table 16.
Maintenance General Inspection Fuel Addition Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 16 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual). Add diesel fuel (the grade may vary according to season and locations).
Maintenance Fuel Tank Inspection Check Oil Level In addition to cleaning the fuel tank, the following components should be inspected for wear: 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 32. Rubber Suspension — look for signs of wear or deformity due to contact with oil.
Maintenance Radiator Cleaning The radiator (Figure 59) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the fins and tube. The purpose of these receptacles is to provide power via commercial power to the water heater and internal battery charger.
Maintenance Emission control The emission control system employed with the John Deere 4045HFG93 diesel engine consist of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). The oxidation catalyst and particulate filter are housed in one unit. See Figure 63. These devices help in filtering out large amounts of harmful Nitrogen Oxides (NOx) and Particulate Matter (PM) which are emitted by diesel engines. These exhaust emissions pose serious environmental and health risks.
Maintenance ECU Forced regeneration procedure Follow the steps below to initiate a forced regeneration: Series 800 Controller Engine Started DPF STAT Shutdown Pre-Alarm 1. Verify that the AMBER pre-alarm LED is ON or FLASHING and the DPF symbol is shown on the ECU display. 2. Place all circuit breakers in the OFF position. 3. Place the engine speed switch in the LOW position. Alarm Screen Acknowledge Change Option Program Exit Figure 62.
Maintenance AUTO regeneration procedure Auto regeneration process will automatically occur. No operator action is required for this process. Allow the engine to run for at least 30 minutes to complete the automatic regeneration process. Reference Table 17 for the various soot level stages for the DPF system. Controller Message DPF Condition Table 17.
Trailer Maintenance The following trailer maintenance guidelines are intended to assist the operator in preventive maintenance. Trailer Brakes 6. Replace the adjusting-hole cover. 7. Repeat the above procedure on all brakes. 8. Lower the trailer to the ground. Properly functioning brake shoes and drums are essential to ensure safety. The brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly.
Trailer Maintenance WARNING ADJUSTABLE CHANNEL Failure to maintain proper fluid level in the actuator may result in loss of braking action which could cause severe property damage, injury or death. Periodically check the actuator mounting fasteners for damage or loosening. Inspect the actuator for worn or damaged parts. As you are towing your trailer, be aware of any changes in braking quality. This could be an early warning of brake or actuator malfunction and requires immediate attention.
Trailer Maintenance After removing the dust cap, cotter pin, spindle nut and spindle washer, remove the hub to inspect the bearings for wear and damage. Replace bearings that have flat spots on rollers, broken roller cages, rust or pitting. Always replace bearings and cups in sets. The inner and outer bearings are to be replaced at the same time. DANGER Improper weld repair will lead to early failure of the trailer structure and can cause serious injury or death.
Trailer GUIDELINES The following guidelines are intended to assist the operator in the operation and handling of a trailer. Shift your automatic transmission into a lower gear for city driving. Safety precautions should be followed at all times when operating a trailer. Failure to read, understand and follow the safety guidelines could result in injury to yourself and others. Loss of control of the trailer or tow vehicle can result in death or serious injury.
Trailer GUIDELINES driving conditions When towing a trailer, you will have decreased acceleration, increased stopping distance, and increased turning radius (which means you must make wider turns to keep from hitting curbs, vehicles, and anything else that is on the inside corner). In addition, you will need a longer distance to pass, due to slower acceleration and increased length. Be alert for slippery conditions.
Trailer GUIDELINES inoperaBle BraKes, lights or mirrors Be sure that the brakes and all of the lights on your trailer are functioning properly before towing your trailer. Check the trailer taillights by turning on your tow vehicle headlights. Check the trailer brake lights by having someone step on the tow vehicle brake pedal while you look at trailer lights. Do the same thing to check the turn signal lights. See Trailer Wiring Diagram section in this manual.
Trailer GUIDELINES VI N TA G VIN TAG Figure B. VIN Tag Location To determine the “empty” or “net” weight of your trailer, weigh it on an axle scale. To find the weight of the trailer using an axle scale, you must know the axle weights of your tow vehicle without the trailer coupled. Some of the trailer weight will be transferred from the trailer to the tow vehicle axles, and an axle scale weighs all axles, including the tow vehicle axles.
Trailer GUIDELINES emergencY Flares and triangle reFlectors Ball hitch coupler It is wise to carry these warning devices even if you are not towing a trailer. It is particularly important to have these when towing a trailer because the hazard flashers of your towing vehicle will not operate for as long a period of time when the battery is running both the trailer lights and tow vehicle lights. A ball hitch coupler (Figure C) connects to a ball that is located on or under the rear bumper of tow vehicle.
Trailer GUIDELINES or is worn, the trailer can come loose from the tow vehicle and may cause death or serious injury. the trailer tongue. Wood or concrete blocks may also be used. THE TOW VEHICLE, HITCH AND BALL MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER gross vehicle Weight rating (gvWr). IT IS ESSENTIAL THAT THE HITCH BALL BE OF THE SAME SIZE AS THE COUPLER.
Trailer GUIDELINES Breakaway Brake system NOTICE Overloading can damage the tongue jack. dO NOT use the tongue jack to raise the tow vehicle more than one inch. If the coupler cannot be secured to the hitch ball, do not tow the trailer. Call your dealer for assistance. Lower the trailer so that its entire tongue weight is held by the hitch and continue retracting the jack to its fully retracted position.
Trailer GUIDELINES connecting trailer lights pintle hitch coupler Connect the trailer lights to the tow vehicle’s electrical system using the electric connectors at the front of the trailer (tongue). Refer to the wiring diagram shown in the trailer wiring diagram section of this manual. Before towing the trailer check for the following: A pintle eye coupler (Figure G) connects to a pintle-hook hitch that is located on or under the rear bumper of the tow vehicle.
Trailer GUIDELINES the ball andcoupler system. All bent or broken coupler parts must be replaced before towing the trailer. THE TOW VEHICLE, PINTLE HITCH AND PINTLE COUPLER MUST HAVE A RATED TOWING CAPACITY EQUAL TO OR GREATER THAN THE TRAILER gross vehicle Weight rating (gvWr). IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE SAME SIZE AS THE PINTLE COUPLER. The coupler size and load rating (capacity) are marked on the coupler. Hitch capacity is marked on the hitch.
Trailer GUIDELINES tire saFetY unsafe tires, lug nuts or Wheels Trailer tires and wheels are more likely to fail than car tires and wheels because they carry a heavier load. Therefore, it is essential to inspect the trailer tires before each tow. If a tire has a bald spot, bulge, cuts, is showing any cords, or is cracked, replace the tire before towing. If a tire has uneven tread wear, take the trailer to a dealer service center for diagnosis.
Trailer GUIDELINES There is a vehicle placard (Figure I) located in the same location as the certification label described above. This placard provides tire and loading information. In addition, this placard will show a statement regarding maximum cargo capacity. TIRE AND LOADING INFORMATION The weight of cargo should never exceed XXX kg. Or XXX lbs. TIRE FRONT REAR SPARE SIZE COLD TIRE PRESSURE SEE OWNER’S MANUAL FOR ADDITIONAL INFORMATION Figure I.
Trailer GUIDELINES Use the information contained in this section to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure. tire Fundamentals Federal law requires tire manufacturers to place standardized information on the sidewall of all tires (Figure J).
Trailer GUIDELINES uniform tire Quality grading standards (utQgs) Treadwear Number: This number indicates the tire’s wear rate. The higher the treadwear number is, the longer it should take for the tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200. traction letter: This letter indicates a tire’s ability to stop on wet pavement. A higher graded tire should allow you to stop your car on wet roads in a shorter distance than a tire with a lower grade.
Trailer GUIDELINES Table B below will help pinpoint the causes and solutions of tire wear problems. table B. Tire Wear Troubleshooting Wear pattern cause Solution Center Wear Over inflation. Adjust pressure to particular load per tire manufacturer. Edge Wear Under inflation. Adjust pressure to particular load per tire manufacturer. Side Wear Loss of camber or overloading. Make sure load does not exceed axle rating. Align wheels. Toe Wear Incorrect toe-in. Align wheels.
Trailer GUIDELINES table c. Tire Torque Requirements Wheel Size First pass Ft-lBs Second pass Ft-lBs Third pass Ft-lBs 12" 20-25 35-40 50-65 13" 20-25 35-40 50-65 14" 20-25 50-60 90-120 15" 20-25 50-60 90-120 16" 20-25 50-60 90-120 Replace any broken or burned-out lamps as necessary. Check the wire harness for cuts, fraying or other damage. If it needs replacing, contact your dealer. Warning Improper operating taillights, stoplights and turn signals can cause collisions.
notes dca70SSJU4i 60 hz generator• operation manual — rev.
Troubleshooting Diagnostics The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. 1. With the engine stopped (OFF). Push and hold the Hour Check Button (Figure 69) located on the control panel. HOUR CHECK BUTTON 5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode.
Troubleshooting generator Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Symptom No Voltage Output Low Voltage Output High Voltage Output Circuit Breaker Tripped Table 19.
Troubleshooting engine troubleshooting (engine) Symptom Engine will not start or start is delayed, although engine can be turned over. At low temperatures engine will not start. Engine fires but stops soon as starter is switched off. Engine stops by itself during normal operation. Low engine power, output and speed. possible problem Solution No Fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump.
Troubleshooting engine (continued) troubleshooting (engine) - continued Symptom Low engine power output and low speed, black exhaust smoke. Engine overheats. possible problem Solution Air filter blocked? Clean or replace air filter. Incorrect valve clearances? Adjust valves per engine specification. Malfunction at injector? See engine manual. Too much oil in engine crankcase? Drain off engine oil down to uppermark on dipstick.
Generator Wiring Diagram Figure 71. Generator Wiring Diagram page 70 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
600 vac auto transformer Wiring Diagram dca70SSJU4i 60 hz generator• operation manual — rev.
Engine Wiring Diagram Figure 72. Engine Wiring Diagram page 72 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
battery charger Wiring Diagram BATTERY CHARGER DC+ BLACK 14 AWG. LINE (L) 120VAC INPUT DC RED 16 AWG. GREEN 16 AWG. WHITE 14 AWG. TO STARTER “B” TERMINAL TO CHASSIS GROUND NEUTRAL (N) 1 GREEN 14 AWG. 2 GROUND (G) NOTES: 1 NEMA 5-15, 15A, 120 VAC (HBL5278C/HUBBLE RECEPTACLE). 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY. Figure 73. Battery Charger Wiring Diagram dca70SSJU4i 60 hz generator• operation manual — rev.
water heating element Wiring Diagram BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) 3 1 4 2 GREEN 14 AWG. GROUND (G) BLOCK HEATER BLACK 14 AWG. 120 VAC HEATING ELEMENT WHITE 14 AWG. GREEN 14 AWG. GROUND NOTES: 1 NEMA 5-15, 15A, 120 VAC (HBL5278C/HUBBLE RECEPTACLE) 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY. 3 NEMA L5-20R, 20A, 125 VAC (HBL5369C/HUBBLE RECEPTACLE). 4 RECEPTACLE IS MOUNTED ADJACENT TO WATER HEATING ELEMENT. Figure 74.
notes dca70SSJU4i 60 hz generator• operation manual — rev.
Explanation of Code in Remarks Column The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. NOTICE The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed. sample parts list no. 1 2% 2% 3 4 part no. part name QtY. remarKs 12345 BOLT .....................1 .....
Suggested Spare Parts DCA70SSJU4i WHISPERWATT GENERATOR with JOHN DEERE 4045HFG92 DIESEL ENGINE 1 to 3 units Qty. P/N Description 3............RE504836..............CARTRIDGE, OIL FILTER 5............RE544394..............CARTRIDGE, FUEL FILTER 5............RE541922..............CARTRIDGE, FUEL PREFILTER 5............RE540710..............CARTRIDGE, BLOW-BY FILTER 3............0602046365...........ELEMENT, AIR 1............R533597................BELT, FAN 1............m2311500003........
GENERATOR ASSY. page 78 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
GENERATOR ASSY. NO. PART NO.
CONTROL BOX ASSY. 45 45A 44A 44B 44C 52A 44 1-5 52 6A 15A 51A 51B 17A 13A 22 17B 12A 49-2 49-1 14 12 55A 55 58 26A 35A 35 38 38A 59 23 60 page 80 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
CONTROL BOX ASSY. NO. 1 1-1 1-2 1-3 1-4 1-5 2 3 4 5 6 6A 7 8 9 10 11 12 12A 13 13A 14 15 15A 16 17 17A 17B 18 19 20 21 22 23 24 25 26 26A 27 28 PART NO.
CONTROL BOX ASSY. (continued) 45 45A 44A 44B 44C 52A 44 1-5 52 6A 15A 51A 51B 17A 13A 22 17B 12A 49-2 49-1 14 12 55A 55 58 26A 35A 35 38 38A 59 23 60 page 82 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
CONTROL BOX ASSY. (continued) NO. 29 30 31 32 33 34 35 35A 36 37 38 38A 39 40 41 42 43 44 44A 44B 44C 45 45A 46 47 48 49 49-1 49-2 49-3 50 51 51A 51B 52 52A 53 54 55 55A 56 57 58 59 60 PART NO.
engine AND Radiator ASSY. page 84 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
engine AND Radiator ASSY. NO. 1 1A 1B 1C 1D 1E 2 3 4 4A 5 5A 6 6A 6B 7 8 9 10 11 12 13 14 15 16 17 18 19 19A 19B 20 20A 21 21A 22 23 23A 24 24A 25 25A 26 27 28 PART NO.
engine AND Radiator ASSY. (continued) page 86 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
engine AND Radiator ASSY. (continued) NO. 29 30 31 32 33 34 34A 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 51A PART NO.
output terminal ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. page 88 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
output terminal ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 11A 11B 12 12A 13 13A 13B 13C 14 15 16 17 18 19 20 21 22 23 24 24-1 25 26 27 28 28A 29 30 31 32 33 34 35 36 37 38 39 40 41 PART NO.
battery ASSY. page 90 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
battery ASSY. NO. PART NO. 1 0602220199 1 0602220199 2 M9310500014 3 M9103000304 4 0602220920 5 M2346900504 6 M2346400104 7 8 0017112025 8A 0040512000 9 011008020 9A 0040508000 PART NAME QTY. REMARKS BATTERY 2 BATTERY, 727MF 1 BATTERY SHEET 1 BATTERY BAND 1 BATTERY BOLT SET 2 BATTERY CABLE 1 BATTERY CABLE 1 CABLE ...............................................................1................MAKE LOCALLY HEX. HEAD BOLT 1 TOOTHED WASHER 1 HEX.
muffler ASSY. page 92 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
muffler ASSY. NO. 1 1-1 1-2 1-3 1-4 1-5 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23A PART NO.
fuel tank ASSY. page 94 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
fuel tank ASSY. NO. 1 1-1 1-2 1-2A 1-2B 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART NO. M2364000002 0605505070 0605501079 0605516090 7538070 M2363200704 M2363200804 M9310500104 011008020 020108060 0222100710 0191302200 0605515109 0191301100 0191300700 0605515109 Y0602042602 Y0605512182 0605515189 PART NAME FUEL TANK FUEL TANK CAP FUEL SENDER UNIT GASKET MACHINE SCREW TANK BAND TANK BAND SUPPORTER SHEET HEX.
ENCLOSURE ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. page 96 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
ENCLOSURE ASSY. NO. 1 2 3 4 5 6 6A 7 8 8A 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23A 23B 24 25 26 27 28 28A 29 30 30A 31 31A 32 33 34 35 36 37 37A 38 38A 39 39A 40 41 PART NO.
ENCLOSURE ASSY. (cont.) ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. page 98 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
ENCLOSURE ASSY. (cont.) NO. 42 43 44 44A 45 46 47 48 49 49A 50 50A 50B 51 52 53 53A 54 54A 55 55A 56 56A 57 57A 58 58A 59 60 60A 61 62 62A 63 64 64A 65 65A 66 67 68 69 70 71 72 73 74 PART NO.
rubber seals ASSY. page 100 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
rubber seals ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NO. 0229200950 Y0228901840 Y0229401180 Y0228900830 0228800680 Y0228900985 Y0229400500 0228900470 0228800580 Y0228800820 0228800540 0229200880 0228901120 0228100560 0228100370 0229200210 Y0229200160 PART NAME RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAI RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER. SEAI RUBBER SEAL RUBBER SEAL RUBBER SEAL QTY.
camlock ASSY. (option) 1 2 9 12 13 14 3 BLACK 4 RED WHITE GREEN 5 6 11 7 8 BLUE 10 page 102 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
camlock ASSY. (option) NO. PART NO. 1 CAMLOK1BKIT 1 CAMLOK1BKITAL 2%# 0016906016 3%# EE6381 4%# EE6378 5%# EE6380 6%# EE6379 7%# EE6382 8%# CL40WTCL125J 9% CAMPAN7085 9# EE56978 10 11 12 13 14 PART NAME QTY. REMARKS CAMLOK, 1 SET........................................................................ 1......... INCLUDES ITEMS W/% CAMLOK, 1 SET ALUMINUM................................................... 1.........
battery charger ASSY. (OPTION) CONNECT TO CHASSIS GROUND 7 1 8 TO STARTER 2 6 4 5 BLACK 3 WHITE GREEN RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL page 104 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
battery charger ASSY. (OPTION) NO. PART NO. 1 LC125002 2 3 EE56557 4 5 6 7 8 PART NAME QTY. REMARKS CHARGER BATTERY, 3 AMP 12V.....................1 GROMMENT, 7/8" HOLE SIZE...........................1................OBTAIN LOCALLY CORD, 3-CONDUCTOR, 14 AWG ..................6 FT...............1PC=1FT SCREW, M4X10.................................................4................OBTAIN LOCALLY WASHER, LOCK M4..........................................4................
heating element ASSY. (OPTION) 2 6 7 1 8 5 9 4 3 RECEPTACLE IS MOUNTED ADJACENT TO HEATER ELEMENT page 106 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
heating element ASSY. (OPTION) NO. PART NO. 1 AR50411 2 EE54798 3 HBL5369C 4 EE56557 5$ 6$ 7$ 8$ 9$ PART NAME QTY. REMARKS CORD ASSY., 110 VOLTS 1 KIT, 110 VOLT, COOLANT HEATER...................1................INCLUDES ITEMS W/ $ CONNECTOR, 20AMP, 125V 1 CORD, CAROL 3/C 14AWG 90C.......................10...............1PC=1FT NUT, CLAMPING 1 ADAPTER 1 O-RING 1 GASKET 1 HEATER ELEMENT, 110V 1 dca70SSJU4i 60 hz generator• operation manual — rev.
3ø 600 vac Transformer ASSY. (OPTION) 3 4 5 7 2 1 9 6 19 1 8 18 17 10 19 15 18A 1 16 BACKSIDE OF DOOR 11 10 11A 3-POLE 70 AMPS CIRCUIT BREAKER DISJONCTEUR 70 AMPS À 3 PÔLES 14 13 12 11B 11C page 108 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
3ø 600 vac Transformer ASSY. (OPTION) NO. PART NO. 1 EE5972 2 EE57531 3 EE57530 4 EE52419 5 EE57532 6 EE57533 7 EE57758 8$ 9 EE57534 10 EE57538 11 11A 11B 11C 12 EE57757 13 EE56924 14 EE57351 15 EE57536 16 EE57535 17 EE22962 18 18A 19 EE57537 PART NAME QTY. REMARKS BUSHING, PLASTIC, 1-1/2" 4 KIT, NEUTRAL, BUS BAR 1 ENCLOSURE, NEMA 3R CIRCUIT BREAKER 1 CIRCUIT BREAKER, 70 AMP 1 MECHANISM, CIRCUIT BREAKER OPERATION 1 SHAFT 1 LABEL, VINYL, 600V 1 SCREW 2 HANDLE, EXTERIOR.........................
trailer trlr70ush ASSY. (OPTION) 22 40 41A 41 41B 39 41C 37 42 10 31 33 30 11 34 9 19 21 8 35 34 36 18 17 13 2 3 7 6 5 5 33 4 12 1 20 14 25 5 23 4 16 15 48 47 43 32 44 46 45 page 110 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
trailer trlr70ush ASSY. (OPTION) NO. PART NO. 1 EE57460 2 EE43077 3 EE43524 4 EE43528 5 EE43606 6 EE44418 7 EE44419 8 EE55966 9 EE34256 10 EE34257 11 EE43536 12 EE43535 13 EE43369 14 EE43527 15 EE43529 16 EE43530 17 EE43524 18 EE55105 19 EE43090 20 EE40139 21 EE43517 22 EE57446 23 EE43513 25 EE43254 30 EE43253 31 EE36264 32$ 29194 33 49928 34 49929 35 0205 36 0166 A 37 701472 39 40 41 EE57470 41A 41B 41C 42 43 44 45 46 47 EE56008 48 PART NAME QTY. REMARKS FRAME ASSY.
trailer trlr70usE ASSY. (OPTION) 22 40 41A 41B 41 39 41C 37 42 10 31 33 30 11 34 9 19 8 35 2 7 3 34 36 21 18 13 6 49 17 5 38 5 33 4 12 1 20 14 25 5 23 4 16 15 48 47 43 32 44 46 45 page 112 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
trailer trlr70usE ASSY. (OPTION) NO. PART NO. 1 EE57460 2 EE43182 3 EE43524 4 EE43528 5 EE43606 6 EE44418 7 EE44419 8 EE55967 9 EE34256 10 EE34257 11 EE43536 12 EE43535 13 EE43369 14 EE43527 15 EE43529 16 EE43530 17 EE43524 18 EE55105 19 EE55278 20 EE40139 21 EE43517 22 EE57446 23 EE43513 25 EE43254 30 EE43253 31 EE36264 32$ 29194 33 49928 34 49929 35 0205 36 0166 A 37 701472 38 EE55276 39 40 41 EE57470 41A 41B 41C 42 43 44 45 46 47 EE56008 48 49 EE43519 PART NAME QTY.
nameplate and decals ASSY. 18A 19A 19 12A 17A 18 7A 25A 20A 53 26A 57 58 11A 29A 15A KIT, DECAL 54A 54 51 51A 52 52A 53A TRAILER 48 KIT, DECAL 40A 55 50 50A 48A 41A 39A 38A 42A 49A 49 56 5A 6A 7A 8A page 114 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
nameplate and decals ASSY. NO. PART NO.
nameplate and decals ASSY. (CONTINUED) 18A 19A 19 12A 17A 18 7A 25A 20A 53 26A 57 58 11A 29A 15A KIT, DECAL 54A 54 51 51A 52 52A 53A TRAILER 48 KIT, DECAL 40A 55 50 50A 48A 41A 39A 38A 42A 49A 49 56 5A 6A 7A 8A page 116 — dca70SSJU4i 60 hz generator • operation and Parts manual — rev.
nameplate and decals ASSY. (CONTINUED) NO. PART NO.
Terms and Conditions of Sale — Parts PAYMENT TERMS 5. Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked. 6. The following items are not returnable: 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. a. SPECIAL EXPEDITING SERVICE Terms of payment for parts are net 30 days.
notes dca70SSJU4i 60 hz generator• operation manual — rev.
Operation and parts Manual HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com MQ Parts Department Tel.