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DCA70USI2 manual Engine And Radiator Assy
Models:
DCA70USI2
1
60
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Troubleshooting
Specification
Install
Parts list
Trailer Wiring Diagram
Warranty
Dimension
Maintenance
Removing the Plastic Face Plate Hard Wire Hookup Panel
Off/Reset
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ENGINE AND RADIATOR ASSY.
page 60 — DCA70USI2 60 hz Generator • operation and parts manual — rev. #0 (06/28/11)
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Contents
PARTS LIST NO. M2870400304C
Operation and Parts Manual
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES
MODEL dca70USI2
proposition 65 warning
Diesel engine exhaust and some of
Reporting Safety Defects
Table of Contents
Component Drawings
Inspection/Setup
Generator Start-Up Procedure
Parts Ordering Procedures Ordering parts has never been easier
Choose from three easy options
When ordering parts, please supply
Best Deal! Order via Internet Dealers Only
Safety Information
SaFeTY meSSageS
SaFeTY SYmBolS
Danger
general SaFeTY
generaTor SaFeTY
Safety Information
never lubricate components or attempt service on a running machine
engIne SaFeTY
Safety Information
Danger
FUel SaFeTY
ToWIng SaFeTY
Safety Information
Danger
eleCTrICal SaFeTY
grounding Safety
power Cord/Cable Safety
death
BaTTerY SaFeTY
envIronmenTal SaFeTY
Safety Information
Use well-insulated gloves when picking up the battery
Specifications
Table 1. Generator Specifications
Model
Model
Dimensions
Table 3. Dimensions
Figure 1. Dimensions
Dimension in. mm
Installation
Figure 2. Typical Generator Grounding Application
Outdoor Installation
Indoor Installation
Mounting
Generator Grounding
General Information
Generator
Engine Operating Panel
Generator Control Panel
Major Components
Table 4. Generator Major Components
ITEM NO
Figure 3. Major Components
Generator Control Panel
Starter Relay Current Transformer Voltage Selector Switch
The Control Box is equipped with the following major components
Over-Current Relay Automatic Voltage Regulator AVR
Page
ENGINE OPERATING PANEL
OFF/RESET
HIGH COOLANT TEMPERATURE
Figure 5. Engine Operating Panel
ENGINE OPERATING PANEL
6. Fuel Gauge - Indicates amount of diesel fuel available
OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
Terminal legs “O” and “Ground” are considered bonded grounds
Removing the Plastic Face Plate Hard Wire Hookup Panel
120 VAC GFCI Receptacles
OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 7. G.F.C.I. Receptacle
Connecting Loads
Over Current Relay
Figure 12. Over Current Relay Figure 11. Connecting Loads
OUTPUT TERMINAL PANEL FAMILIARIZATION
Single Phase Load
Three Phase Load
Table 5. Power Factor By Load
Load Application
Voltage Selector Switch
Voltage Selector Switch Locking Button
GENERATOR OUTPUTS
Generator Output Voltages
How to Read the ac ammeter and ac voltage gauges
GENERATOR OUTPUTS/gauge reading
AC Voltmeter Gauge Reading
AC Ammeter Gauge Reading
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240/139 UVWO Terminal Output Voltages
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
Figure 24. Voltage Selector Switch 3Ø-480/277V Position
Figure 26. Voltage Selector Switch 1Ø-240/120V Position
inspection/SETUP
Circuit Breakers
Lubrication Oil
Fuel Check
Refueling Procedure
ONLY use #2 diesel fuel when refueling
inspection/SETUP
Figure 30. Only Fill on Level Ground
Cleaning the Radiator
Air Cleaner
Coolant Antifreeze/Summer Coolant/ Water
Operation in Freezing Weather
Battery
Battery Cable Installation
Wiring
Alternator
GENERATOR START-UP PROCEDURE
Before Starting
Starting
Starting Manual
GENERATOR START-UP PROCEDURE
Figure 42. Engine Speed Switch High
Figure 46. Voltage Adjust Control Knob
Figure 49. Coolant Temperature Gauge
GENERATOR SHUT-DOWN PROCEDURES
Normal Shutdown Procedure
Emergency Shutdown Procedure
Automatic Shut-down System
Maintenance
Air Cleaner with Dust Indicator
General Inspection
Air Cleaner
Cleaning Inside the Fuel Tank
Fuel Addition
Removing Water from the Fuel Tank
Fuel Tank Inspection
Radiator Cleaning
Check Oil Level
Replacing Oil Filter
Flushing Out Radiator and Replacing Coolant
Trailer Maintenance
Trailer Maintenance
Brake Adjustment
Brakes
Hydraulic Surge Brakes
Actuator
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Suspension
Trailer Maintenance
Lug Nut Torque Requirements
Trailer Maintenance
Figure 61. Wheel Lug Nuts Tightening Sequence
Table 18. Tire Torque Requirements
Trailer Wiring Diagram
Figure 62. Trailer/Towing Vehicle Wiring Diagram
Generator Wiring Diagram
Figure 63. Generator Wiring Diagram
Engine Wiring Diagram
Figure 64. Engine Wiring Diagram
controller Wiring Diagram
Figure 65. Engine Controller
Troubleshooting Generator
Table 19. Generator Troubleshooting
Symptom
Possible Problem
Troubleshooting Diagnostic lamp
Method of Operation
Sample partS liSt
Explanation of Code in Remarks Column
NO. Column
part NO. Column
Suggested Spare Parts
1 to 3 units
Description
GENERATOR ASSY
PART NAME
QTY. REMARKS
GENERATOR ASSY
control box ASSY
REMARKS
control box ASSY
PART NAME
AUTOMATIC VOLTAGE REGULATOR
control box ASSY
CHANGE- OVER SWITCH, AMMETER
CHANGE-OVER SWITCH, VOLTMETER
control box ASSY
PART NAME
control box ASSY
WIRE HARNESS, GENERATOR
WIRE HARNESS, CONTROLLER
control box ASSY
PART NAME
ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NAME
REMARKS
RADIATOR HOSE, UPPER, SHORT
ENGINE AND RADIATOR ASSY. continued
SENSOR, WATER TEMPERATURE
ENGINE AND RADIATOR ASSY. continued
PART NAME
REMARKS
OUTPUT TERMINAL ASSY
OUTPUT TERMINAL ASSY
PART NAME
REMARKS
SUPPORTER, CABLE OUTLET COVER
BATTERY ASSY
BATTERY ASSY
PART NAME
REMARKS
CABLE
Muffler Assy
Muffler Assy
PART NAME
REMARKS
REPLAC ES P/N
FUEL TANK ASSY
FUEL TANK ASSY
PART NAME
REMARKS
FUEL FILTER MAIN
ENCLOSURE #1 ASSY
ENCLOSURE #1 ASSY
PART NAME
REMARKS
ENCLOSURE ASSY. #1 continued
ENCLOSURE ASSY. #1 continued
PART NAME
REMARKS
ENCLOSURE 2 ASSY
ENCLOSURE 2 ASSY
PART NAME
RUBBER SEALS ASSY
REMArks
RUBBER SEALS ASSY
PART NAME
NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
PART NAME
REMARKS
S/N 8801496 AND ABOVE
Terms and Conditions of Sale - Parts
SPECIAL EXPEDITING SERVICE
PAYMENT TERMS
FREIGHT POLICY
Page
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Service Department
Warranty Department