Multiquip DCA85usJ2 manual

OPERA TION AND P AR TS MANUAL THIS MANU AL MUST A CCOMP ANY THE EQUIPMENT A T ALL TIMES. To fi nd the latest revision of this publication, visit our website at: www .multiquip.com ® MODEL DCA85USJ2 60HZ GENERA TOR (JOHN DEERE 4045HF285 DIESEL ENGINE) P AR TS LIST NO. M2870400404C Re vision #1 (03/22/11)[...]

P A GE 2 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) PROPOSITION 65 W ARNING Diesel engine exhaust and some of[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 3 If you belie ve that your v ehicle has a defect that could cause a crash or could cause injur y or death, you should immediately inf or m the National Highway T raffi c Safety Administr ation (NHTSA) in addition to notifying Multiquip at 1-800-421-12[...]

P A GE 4 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) T ABLE OF CONTENTS DCA-85USJ2 Generator Proposition 65 Warning ........................................... 2 Repor ting Safety Def ects ......................................... 3 T able Of Contents ....................................................[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 5 P AR TS ORDERING PROCEDURES www .multiquip .com Or dering par ts has never been easier! Choose fr om three easy options: WE A CCEPT ALL MAJOR CREDIT CARDS! When or dering par ts, please supply: ❒ Dealer Account Number ❒ Dealer Name and Address ❒[...]

P A GE 6 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) SAFETY INFORMA TION Do not operate or service the equipment before reading the entire manual. Saf ety precautions should be follo wed at all times when operating this equipment. F ailure to read and understand the saf ety messages and operating instru[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 7 SAFETY INFORMA TION GENERAL SAFETY CA UTION  NEVER operate this equipment without proper protectiv e clothing, shatter proof glasses, respiratory protection, hearing protection, steel-toed boots and other protective de vices required by the job or [...]

P A GE 8 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) SAFETY INFORMA TION ENGINE SAFETY D ANGER  The engine fuel e xhaust gases contain poisonous carbon mono xide. This gas is color less and odorless, and can cause death if inhaled.  The engine of this equipment requires an adequate free fl ow of [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 9 SAFETY INFORMA TION FUEL SAFETY D ANGER  DO NO T star t the engine near spilled fuel or comb ustible fl uids. Diesel fuel is e xtremely fl ammable and its v apors can cause an e xplosion if ignited.  AL W A YS refuel in a well-ventilated area,[...]

P A GE 10 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) SAFETY INFORMA TION ELECTRICAL SAFETY D ANGER  DO NO T touch output ter minals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or b urn.  The electrical voltage required to operate the [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 11 SAFETY INFORMA TION B A TTER Y SAFETY D ANGER  DO NO T drop the batter y . There is a possibility that the batter y will e xplode.  DO NO T expose the battery to open fl ames, sparks, cigarettes, etc. The batter y contains combustib le gases a[...]

P A GE 12 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) SPECIFICA TIONS T able 1. Generator Specifi cations Model DCA-85USJ2 T ype Rev olving fi eld, self ventilated, open protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase 3 Single Standby Output 75 KW (94 kV A) 66 K[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 13 DIMENSIONS Figure 1. Dimensions T able 3. Dimensions Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) A 42.51 in. (1080 mm.) F 112.20 in. (2,850 mm.) B 32.13 in. (816 mm.) G 71.26 in. (1,810 mm.) C 33.30 in. (846 mm.) H 48.82 i[...]

P A GE 14 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) INST ALLA TION Figure 2. T ypical Generator Grounding Application[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 15 INST ALLA TION OUTDOOR INST ALLA TION Install the generator in a area that is free of debris, bystanders , and ov erhead obstructions. Make sure the generator is on secure le v el ground so that it cannot slide or shift around. Also install the gener[...]

P A GE 16 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR This generator (Figure 3) is a high quality por table (requires a trailer f or transpor t) power source f or telecom sites, lighting f acilities, pow er tools, submersible pumps and other industrial and constr uction machiner y . ENGINE OP[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 17 MAJOR COMPONENTS Figure 3. Major Components T able 4. Generator Major Components ITEM NO . DESCRIPTION 1 Muffl er Assembly 2 Engine Assembly 3 Air Filter Assembly 4 Generator Assemb ly 5 Batter y Assembly 6 Output T er minal Assembly 7 Fuel T ank As[...]

P A GE 18 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) DIAGNOSTIC DISPLA Y Figure 4. Diagnostic Display The diagnostic displa y panel located inside the control box on the generator (Figure 4) is designed to meet the needs f or instrumentation and control of electronically controlled engine communication[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 19 DIAGNOSTIC DISPLA Y First Time Start Up 1. When power is fi rst applied to the diagnostic display , the “Logo” is display ed. 2. The “W ait to Star t” message will be displa yed f or engines with a pre-star tup sequence. Once the “W ait to[...]

P A GE 20 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) 2 . The language choices will be displa yed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection. 3. No w that you ha ve selected the language , touch the “Menu” button to retur n to the main men[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 21 DIAGNOSTIC DISPLA Y First Time Star t-Up 1. When power is fi rst applied to the diagnostic display , the “Logo” is display ed. 2. The “W ait to Star t” message will be displa yed f or engines with a pre-star tup sequence. Once the “W ait t[...]

P A GE 22 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) 2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection. 3. Now that you ha v e selected the language, touch the “Menu” button to retur n to the main menu d[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 23 2. The main menu will pop up on the displa y . Use the “Arrow Buttons” to scroll through the menu until the “Engine Confi guration” menu item has been highlighted . 3. Once the “Engine Confi guration” menu item has been highlighted touc[...]

P A GE 24 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) DIAGNOSTIC DISPLA Y 5. T ouching the “Enter Button” will redisplay the hidden f ault. T ouching the “Enter Button” once again will hide the f ault and retur n the screen to the single or four parameter displa y . NO TE: The fault can only be [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 25 DIAGNOSTIC DISPLA Y Shutdown Codes 1. Dur ing nor mal operation the single or f our parameter screen will be displa yed 2. When the diagnostic displa y receives a se vere f ault code from an engine control unit the single or f our parameter screen wi[...]

P A GE 26 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) DIAGNOSTIC DISPLA Y 3. Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Backlight” function 4. Use the “Arro w Buttons” to select the desired backlight intensity . . 5. T ouch[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 27 Select Units 1. Star ting at the single or four engine parameter displa y touch the “Menu Button” . 2. The main menu will pop up on the displa y . Use the arrow b uttons to scroll through the menu until the “Select Units” is highlighted. 3. O[...]

P A GE 28 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) 3. Once the “Setup 1-up Displa y” menu icon has been highlighted touch the “Enter Button” to access the “Setup 1-up displa y” function. 4. Three options are av ailable f or modifi cation of the 1-Up displa y . a. Use Defaults — This op[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 29 DIAGNOSTIC DISPLA Y 11 . T ouch the “Enter Button” to deselect the selected parameter removing it from the list of par ameters being displa yed on the 1-up displa y . 12. Use the “Arrow Button” to scroll and highlight the desired parameter th[...]

P A GE 30 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) Setup 4-Up Display 1. F rom the single or f our engine parameter displa y touch the “Menu Button 2. The main menu will pop up on the displa y . Use the “Arrow Buttons” to scroll through the menu until the “Setup 4-Up Displa y” is highlighte[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 31 DIAGNOSTIC DISPLA Y 9. The parameter that is highlighted is the selected parameter f or the screen. Use the “Arro w Buttons” to highlight the new par ameter to be placed in the quadrant selected in the pre vious screen. 1 0. T ouch the “Enter B[...]

P A GE 32 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) DIAGNOSTIC DISPLA Y 4. T ouch “Select” to enter the “Gage Data” displa y . When “Gage Data” is selected the P owerVie w will communicate with the analog gages at a fi x ed rate of 38.4k Band, 8 data bits, no parity check, 1 stop bits , h[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 33 DIAGNOSTIC DISPLA Y 11. T ouch the “Menu” button to retur n to “Utilities” menu. T ouch the “Menu button again to return to the “Main” menu. MODBUS SETUP 1. Star ting at the single or four engine parameter displa y , touch the “Menu B[...]

P A GE 34 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) DIAGNOSTIC DISPLA Y GLOSSAR Y (T roubleshooting Inf ormation) CANBUS F AILURE Diagnostic Displa y has not received an y CAN messages for at least 30 seconds . NO D A T A Diagnostic Displa y has not received the particular message being display ed for[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 35 GENERA TOR CONTROL P ANEL Figure 5. Generator Control P anel OFF W U V OFF W-U V-W U-V DECREASE INCREASE 1 AUTO MANUAL OFF/RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO-20001Q 2 3 4 6 7 5 The defi nitions [...]

P A GE 36 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENGINE OPERA TING P ANEL Figure 6. Engine Operating Panel OFF W U V OFF W-U V- W U-V DECREASE INCREASE 1 2 3 4 5 AUTO MANUAL OFF/RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO-20001Q 14 7 6 8 9 10 11 12 13 T[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 37 ENGINE OPERA TING P ANEL 10. Warning Lamp – This lamp will illuminate when a critical engine fault has occured. 11. Pre-Heat Lamp – As the engine cranks, this lamp will illuminate to indicate automatic preheating of the engine. When the lamp turn[...]

P A GE 38 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) OUTPUT TERMINAL P ANEL F AMILIARIZA TION OUTPUT TERMINAL P ANEL The Output T er minal Panel (Figure 7) sho wn 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 [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 39 OUTPUT TERMINAL P ANEL F AMILIARIZA TION 120 V A C GFCI Receptacles There are two 120 V AC , 20 amp GFCI (Duple x Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any v oltage selector switch positio[...]

P A GE 40 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) OUTPUT TERMINAL P ANEL F AMILIARIZA TION Connecting Loads Loads can be connected to the generator b y the Output T erminal Lugs or the conv enience receptacles (Figure 12). Make sure to read the oper ation manual bef ore attempting to connect a load [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 41 LOAD APPLICA TION SINGLE PHASE LO AD Alwa ys be sure to check the nameplate on the generator and equipment to insure the wattage , amperage, frequency , and voltage requirements are satisf actor ily supplied by the generator f or operating the equipm[...]

P A GE 42 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR OUTPUTS GENERA TOR OUTPUT V OL T A GES A wide range of v oltages are av ailable to supply v oltage for many diff erent applications. V oltages are selected by using the volta ge selector switch (Figure 14). T o obtain some of the voltages [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 43 GENERA TOR OUTPUTS/GAUGE READING HO W TO READ THE A C AMMETER AND AC V OL T A GE GA UGES The A C ammeter and AC v oltmeter gauges are controlled by the A C ammeter and AC v oltmeter change-ov er s witches. Both of these s witches are located on the c[...]

P A GE 44 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) OUTPUT TERMINAL P ANEL CONNECTIONS UVWO TERMINAL OUTPUT V OL T A GES V ar ious output voltages can be obtained using the UVW O output ter minal lugs. The voltages at the terminals are dependent on the position of the V oltage Selector Switch and the [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 45 OUTPUT TERMINAL P ANEL CONNECTIONS 3Ø-480/277V UVWO T erminal Output V oltages 1. Place the voltage selector s witch in the 3Ø 480/277 position as shown in Figure 25. Figure 25. V oltage Selector Switch 3Ø-480/277V P osition 2. Connect the load wi[...]

P A GE 46 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) INSPECTION/SETUP CIRCUIT BREAKERS T o protect the generator from an ov er load, a 3-pole, 400 amp , main circuit breaker is pro vided to protect the U, V , and W Output T erminals from overload. In addition two single-pole, 20 amp GFCI circuit breake[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 47 INSPECTION/SETUP Refueling Procedure: 1. Level T anks — Make sure fuel cells are le vel with the ground. F ailure to do so will cause fuel to spill from the tank bef ore reaching full capacity (Figure 31). Figure 31. Only Fill on Level Gr ound W AR[...]

P A GE 48 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) COOLANT (ANTIFREEZE/SUMMER COOLANT/ W A TER) John Deere recommends John Deere antifreeze/summer coolant f or use in their engines, which can be purchased in concentrate (and mix ed with 50% demineralized w ater) or pre-diluted. See the John Deere Eng[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 49 B A TTER Y This unit is of negative g round DO NO T connect in re verse . Alwa ys maintain batter y fl uid lev el between the specifi ed marks. Batter y life will be shortened, if the fl uid le vel are not properly maintained. Add only distilled w[...]

P A GE 50 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR ST AR T -UP PROCEDURE (MANUAL MODE) BEFORE ST ARTING 1. Place the main, G.F .C.I., and aux. circuit break ers (Figure 37) in the OFF position prior to star ting the engine. Figure 37. Main, A ux. and GFCI Circuit Breaker s (OFF) 2. Make su[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 51 GENERA TOR ST AR T -UP PROCEDURE (MANUAL MODE) 4. Once the engine star ts, let the engine run for 1-2 minutes. Listen for an y abnor mal noises. If any abnor malities e xist, shut down the engine and correct the problem. If the engine is r unning smo[...]

P A GE 52 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR ST AR T -UP PROCEDURE (MANUAL MODE) 12. The tachometer gauge (Figure 51) will indicate the speed of the engine when the generator is operating. Under nor mal operating conditions this speed is appro ximately 1800 RPM’ s. Figure 51. Engin[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 53 GENERA TOR SHUT -DOWN PROCEDURES NORMAL SHUTDO WN PROCEDURE T o shutdown the generator , use the following procedure: 1. Place both the MAIN, GFCI and LO AD circuit breakers as shown in Figure 56 to the OFF position.. Figure 56. Main, GFCI and Load C[...]

P A GE 54 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) * 1 Replace engine oil and fi lter at 100 hours , fi rst time only . * 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant. * 3 Replace pr imary air fi lter element when restriction indicator shows a v acuum of 625 [...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 55 MAINTENANCE If the engine is operating in v er y dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power , excessiv e carbon buildup in the comb ustion chamber and high fuel consumption. Change air cleaner m[...]

P A GE 56 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) CHECK OIL LEVEL Check the cr ankcase oil lev el pr ior to each use, or when the fuel tank is fi lled. Insuffi cient oil may cause se vere damage to the engine. Make sure the generator is le vel. The oil le vel m ust be between the two notches on th[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 57 TRAILER MAINTENANCE TRAILER MAINTENANCE This section is intended to provide the user with generic trailer service and maintenance information. The ser vice and maintenance guidelines ref erenced in this section refer to a wide range of trailers . Rem[...]

P A GE 58 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) TRAILER MAINTENANCE BRAKES T railer brak es should be inspected the fi rst 200 miles of operation. This will allow the brake shoes and drums to seat properly . After the fi rst 200 mile inter val, inspect the brak es every 3,000 miles. If driving o[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 59 TRAILER MAINTENANCE TIRES/WHEELS/LUG NUTS Tires and wheels are a very impor tant and cr itical components of the trailer . When specifying or replacing the trailer wheels it is impor tant the wheels, tires, and axle are properly matched. Tire W ear/I[...]

P A GE 60 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) TRAILER MAINTENANCE Lug Nut T orque Requirements It is e xtremely impor tant to apply and maintain proper wheel mounting torque on the trailer . Be sure to use only the f asteners matched to the cone angle of the wheel. Proper procedure f or attachme[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 61 TRAILER WIRING DIAGRAM Figure 65. T railer/T owing V ehicle Wiring Diagram[...]

P A GE 62 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR WIRING DIAGRAM Figure 66. Generator Wiring Diagram[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 63 ENGINE WIRING DIAGRAM Figure 67. Engine Wiring Diagram[...]

P A GE 64 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) TROUBLESHOOTING (GENERA TOR) Practically all breakdowns can be pre vented b y proper handling and maintenance inspections, but in the e vent of a breakdown, use T able 19 sho wn below f or diagnosis of the Generator . If the problem cannot be remedie[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 65 TROUBLESHOOTING (ENGINE CONTROLLER) Practically all breakdowns can be pre vented b y proper handling and maintenance inspections, but in the e vent of a breakdown, use T able 20 (Engine Controller T roubleshooting) as a basic guideline f or troublesh[...]

P A GE 66 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) EXPLANA TION OF CODE IN REMARKS COLUMN The f ollowing section e xplains the different symbols and remarks used in the P ar ts section of this manual. Use the help numbers f ound on the back page of the manual if there are any questions . SAMPLE P ART[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 67 SUGGESTED SP ARE P AR TS DCA85USJ2 WHISPER W A TT GENERA T OR WITH JOHN DEERE4045HF285 DIESEL ENGINE 1 to 3 units QTY . P/N DESCRIPTION 5............RE504836 ............. CARTRIDGE , OIL FIL TER 5............RE529643 ............. FIL TER, FUEL, CAR[...]

P A GE 68 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) GENERA TOR ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 69 GENERA TOR ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 B6110100102 RO T OR ASSY .............................. 1 ........... INCLUDES ITEMS W/# 1-1# FIELD ASSY 1 1-2# 8101070033 F AN 1 1-3# 0012810035 HEX HEAD BOL T 8 1-4# 8101611004 COUPLING D[...]

P A GE 70 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) CONTROL BOX ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 71 CONTROL BOX ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M2213001702 CONTROL BO X ..........................................1 ................ S/N 8400985 AND BELOW 1 M2213001712 CONTROL BO X ..........................................1 .........[...]

P A GE 72 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) CONTROL BOX ASSY . (CONTINUED)[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 73 CONTROL BOX ASSY . (CONTINUED) NO . P ART NO . P ART NAME QTY . REMARKS 31 M4266600004 RESISTOR UNIT 1 32 0027105016 MA CHINE SCREW 1 33 0601802218 HOLDER, FUSE 1 33A 0601806653 FUSE (RIGHT SIDE), 20A 1 33B 0601802149 FUSE ( CENTER), 10A 1 34 0027103[...]

P A GE 74 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) CONTROL BOX ASSY . (CONTINUED)[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 75 CONTROL BOX ASSY . (CONTINUED) NO . P ART NO . P ART NAME QTY . REMARKS 68 M3223100004 STOPPER 1 69 0027105010 MA CHINE SCREW 4 70 0027105010 MA CHINE SCREW 4 71 M9220100004 SET SCREW 2 72 0080200007 SNAP RING 2 73 0602122272 UNIT , OIL PRESSURE 1 74[...]

P A GE 76 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENGINE AND RADIA TOR ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 77 ENGINE AND RADIA TOR ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M2923200094 ENGINE, JOHN DEERE 4045HF285 1 1A R135680 F AN BEL T .................................................... 1 ................ REPLACES P/N 0602015233 1-1 RE504836 CARTR[...]

P A GE 78 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENGINE AND RADIA TOR ASSY . (CONTINUED)[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 79 ENGINE AND RADIA TOR ASSY . (CONTINUED) NO . P ART NO . P ART NAME QTY . REMARKS 38 0605511395 V AL VE .........................................................1 ................ S/N 8400995 AND BELOW 38 0605511399 V AL VE ...........................[...]

P A GE 80 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) OUTPUT TERMINAL ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 81 OUTPUT TERMINAL ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M3230700003 TERMINAL P ANEL 1 2 M9220100304 OUTPUT TERMINAL BOL T 5 3 M9220100404 TIE BOL T 5 4 0039316000 HEX NUT 10 5 0040016000 W ASHER, LOCK 15 6 0041416000 W ASHER, FLA T 20 7 001[...]

P A GE 82 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) BA TTER Y ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 83 BA TTER Y ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 0602220199 BA TTER Y 1 2 M9310500014 BA TTER Y SHEET 1 3 M9103000304 BA TTER Y BAND 1 4 0602220920 BA TTER Y BOL T SET 2 5 M4346900304 BA TTER Y CABLE 1 6 M2346900304 BA TTER Y CABLE 1 7 CAB[...]

P A GE 84 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) MUFFLER ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 85 MUFFLER ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M2330101303 MUFFLER 1 2 0017112030 HEX HEAD BOL T 4 3 M2333001603 EXHA UST PIPE 1 4 M2333200204 GASKET 1 5 0017110050 HEX HEAD BOL T 4 6 0602325066 CLAMP 1 7 M3330401104 CO VER, EXHA UST PIPE [...]

P A GE 86 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) FUEL T ANK ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 87 FUEL T ANK ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M2363000902 FUEL T ANK 1 1-1 0605505070 FUEL T ANK CAP 1 1-2 0605501073 FUEL SENDER UNIT 1 1-2A 0605516090 GASKET 1 2 M2363200404 T ANK BAND 3 3 M2363200904 T ANK BAND 3 4 M9310500104 SUPPO[...]

P A GE 88 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENCLOSURE (1) ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 89 ENCLOSURE (1) ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M2413002202 BASE 1 2 M2363300703 ENVIRONMENT AL T ANK 1 3 0016910030 HEX HEAD BOL T 12 4 0603306797 PLUG 1 5 M2423002102 FRONT FRAME 1 5A M2493108903 ACOUSTIC SHEET 1 6 M2423002202 FRONT[...]

P A GE 90 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENCLOSURE (1) ASSY . (CONTINUED)[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 91 ENCLOSURE (1) ASSY . (CONTINUED) NO . P ART NO . P ART NAME QTY . REMARKS 34 M2463200603 DUCT 1 34A M2493502104 ACOUSTIC SHEET 1 35 0016908020 HEX HEAD BOL T 10 36 M2463400203 DUCT CO VER 1 37 0016908020 HEX HEAD BOL T 6 38 M2423200814 O VER CO VER, [...]

P A GE 92 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENCLOSURE (2) ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 93 ENCLOSURE (2) ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M3443001902 REAR FRAME 1 1A M3493308603 ACOUSTIC SHEET 1 2 M3443002004 DUCT 2 3 0016908020 HEX HEAD BOL T 6 4 M2443400003 P ANEL, REAR FRAME 1 4A M2493305604 ACOUSTIC SHEET 1 4-1 0314501[...]

P A GE 94 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) ENCLOSURE (2) ASSY . (CONTINUED)[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 95 NO . P ART NO . P ART NAME QTY . REMARKS 29 M9113000002 DOOR HANDLE ASSY 4 29A C9312500004 RUBBER SEAL 4 30 0021806016 MA CHINE SCREW 16 30A 0030006000 HEX NUT 16 31 M9110100804 HINGE 6 32 M9110100904 HINGE 5 33 M9116100004 W ASHER 11 34 0019208020 H[...]

P A GE 96 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) RUBBER SEALS ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 97 RUBBER SEALS ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 0229201240 R UBBER SEAL 4 2 0229201130 R UBBER SEAL 1 3 0314502550 R UBBER SEAL 1 4 0229200125 R UBBER SEAL 4 5 0228901165 R UBBER SEAL 3 6 0228900850 R UBBER SEAL 4 7 0228901105 R UBBER [...]

P A GE 98 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) NAMEPLA TE AND DECALS ASSY .[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 99 NAMEPLA TE AND DECALS ASSY . NO . P ART NO . P ART NAME QTY . REMARKS 1 M1550000204 DECAL : NOTE ........................................................ 1 ............ M15000020 2 M1550002203 DECAL : A UXULIAR Y OUTPUT ..............................[...]

P A GE 100 — DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) TERMS AND CONDITIONS OF SALE — P AR TS P A YMEN T TERMS T er ms of payment for parts are net 3 0 days. FREIGHT P OLIC Y All parts orders will be shipped collect or prepaid with the c harges add ed to the invoice. All shipments are F .O .B. point o[...]

DCA85USJ2 60 HZ GENERA T OR • OPERA TION AND P ARTS MANU AL — REV . #1 (03/22/11) — P A GE 101 NOTES[...]

OPERA TION AND P AR TS MANUAL Y our Local Dealer is: HERE’S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED ST A TES Multiquip Corporate Office MQ P ar ts Department 18910 Wilmington A ve . Carson, CA 90746 Contact: mq@multiquip .com T el. (800) 421-1244 F ax (800) 537-3927 800-427-1244 310-537-3700 F ax: 800[...]