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Multiquip operation manual Operation And Parts Manual, MODEL DCA125USJ, Hz GENERATOR

Models: DCA125USJ

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OPERATION AND PARTS MANUAL

MODEL DCA125USJ

60 Hz GENERATOR

(JOHN DEERE 6068TF 275 DIESEL ENGINE)

PARTS LIST NO. M3870400004

Revision #2 (01/27/11)

To find the latest revision of this publication, visit our website at: www.multiquip.com

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.

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Multiquip operation manual Operation And Parts Manual, MODEL DCA125USJ, Hz GENERATOR, Revision #2 01/27/11

Contents

PARTS LIST NO. M3870400004 OPERATION AND PARTS MANUALMODEL DCA125USJ 60 Hz GENERATORPAGE 2 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE NOTE PAGESpecification and part TABLE OF CONTENTSNOTEnumber are subject to change without notice MQ POWER DCA12USJWhen ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Choose from three easy optionsTable 1. Generator Specifications DCA-125USJ - SPECIFICATIONSTable 2. Engine Specifications PAGE 6 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11Figure 1. Dimensions DCA-125USJ - DIMENSIONS TOP, SIDE AND FRONTDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE SAFETY MESSAGES DCA-125USJ - SAFETY INFORMATIONSAFETY SYMBOLS DANGERGENERAL SAFETY DCA-125USJ - SAFETY INFORMATIONGENERATOR SAFETY ﬁre extinguisherDCA-125USJ - SAFETY INFORMATION ENGINE SAFETYDANGER „ NEVER operate the engine with heat shields or guards removedTOWING SAFETY FUEL SAFETYDCA-125USJ - SAFETY INFORMATION DANGERGrounding Safety ELECTRICAL SAFETYPower Cord/Cable Safety DCA-125USJ - SAFETY INFORMATIONENVIRONMENTAL SAFETY BATTERY SAFETYDCA-125USJ - SAFETY INFORMATION DANGERFigure 2. Generator Decals DCA-125USJ - GENERATOR DECALSPAGE 14 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 Figure 3. Generator Decals Cont DCA-125USJ - GENERATOR DECALSDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE Figure 4. Typical Generator Grounding Application DCA-125USJ - INSTALLATIONPAGE 16 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 Outdoor Installation DCA-125USJ - INSTALLATIONIndoor Installation CAUTION - EXHAUST HAZARDDCA-125USJ Series Familiarization Generator DCA-125USJ - GENERAL INFORMATIONEngine Operating Panel Generator Control PanelMuffler Assembly DCA-125USJ - MAJOR COMPONENTSEngine Assembly Enclosure AssemblyPAGE 20 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 NOTE PAGE Current Transformer  Voltage Selector Switch DCA-125USJ - GENERATOR CONTROL PANELThe Control Box is equipped with the following major components  Over-Current Relay  Voltage Rectifer AVR  Starter RelayFigure 7. Engine Operating Panel DCA-125USJ - ENGINE OPERATING PANELPAGE 22 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENGINE OPERATING PANEL Output Terminal Familiarization DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Panel The “OutputTerminal Panel ” Figure 8 is provided with the120VAC GFCI Receptacles DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATIONTwist Lock Dual Voltage 120/240 VAC Receptacles Figure 13. Connecting Loads Over Current Relay Connecting LoadsBlower Fan Figure 15. Blower Fan FuseThree Phase Load Single Phase LoadDCA-125USJ - LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSFigure 16. Voltage Selector Switch Voltage Selector SwitchVoltage Selector Switch Locking Button DCA-125USJ - GENERATOR OUTPUTSFigure 17. Voltage Selector Switch 139VThree Phase Position How to Read the OutputTerminal GaugesDCA-125USJ - GAUGE READING Reading AmperageUVWO Terminal Output Voltages DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONS3Ø 240/139 Output Terminal Lug Voltages 3Ø 208V/1Ø120V Output Terminal Lug Voltages3Ø 480/277 Output Terminal Lug Voltages DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONS1Ø 240V/120V Output Terminal Lug Voltages Circuit Breakers DCA-125USJ - PRE-SETUPLubrication Oil Fuel CheckWARNING - RESPIRATORY HAZARDS Refueling Procedurerefueling DCA-125USJ - PRE-SETUPAir Cleaner Cleaning the RadiatorTable 12. Anti-Freeze Operating Temperatures WARNING - BURN HAZARDSBattery Cable Installation BatteryCAUTION - BATTERY SERVICING SAFETY WiringBefore Starting DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALCAUTION - LETHAL EXHAUST HAZARD WARNING - STARTINGTHE GENERATORFigure 50. Coolant Temperature Gauge DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALFigure 46. Voltmeter Figure 47. Voltage Adjust Control Knob Figure 45. Frequency Meter HzWARNING - AUTO MODE MAINTENANCE DCA-125USJ - GENERATOR START-UP PROCEDURE AUTO MODECAUTION - ENGINE SPEED SWITCH CAUTION - BACKUP GENERATOR USENormal Shutdown Procedure DCA-125USJ - GENERATOR SHUT-DOWN PROCEDUREEmergency Shutdown Procedure Figure 55. MPEC Control Switch Off/ResetAir Cleaner with Dust Indicator DCA-125USJ - MAINTENANCEService Daily General InspectionAir Removal DCA-125USJ - MAINTENANCECheck Oil Level Replacing Oil FilterDCA-125USJ - MAINTENANCE battery chargerBrake Adjustment DCA-125USJ -TRAILER BRAKES MAINTENANCEBrakes Hydraulic Surge BrakesTires/Wheels/Lug Nuts DCA-125USJ -TRAILER MAINTENANCECAUTION - EYESIGHT HAZARD SuspensionLug Nut Torque Requirements DCA-125USJ -TRAILER MAINTENANCEFigure 59. Wheel Lug Nuts Tightening Sequence DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGEFigure 60. Trailer/Towing Vehicle Wiring Diagram DCA-125USJ -TRAILERWIRING DIAGRAMPAGE 46 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 Figure 61. Generator Wiring Diagram DCA-125USJ - GENERATORWIRING DIAGRAMDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE Figure 62. Engine Wiring Diagram DCA-125USJ - ENGINEWIRING DIAGRAMPAGE 48 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 TABLE 18. GENERATOR TROUBLESHOOTING DCA-125USJ -TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMTABLE 19. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-125USJ -TROUBLESHOOTING ENGINE CONTROLLERPAGE 50 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE NOTE PAGEDCA-125USJ - EXPLANATION OF CODE IN REMARKS COLUMN SAMPLE PARTS LISTQTY. Column NO. ColumnDescription DCA-125USJ - SUGGESTED SPARE PARTSDCA-125USJW/JOHN DEERE 4045TF275 DIESEL ENGINE 1 TO 3 UNITS Part number on this Suggested Spare PartsGENERATOR ASSY DCA-125USJ - GENERATOR ASSYPAGE 54 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - GENERATOR ASSYREMARKS CONTROL BOX ASSY DCA-125USJ - CONTROL BOX ASSYPAGE 56 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - CONTROL BOX ASSYREMARKS FCF-6 45~65HzPAGE 58 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - CONTROL BOX ASSYWIRE HARNESS, GENERATOR DCA-125USJ - CONTROL BOX ASSYPART NAME REMARKSENGINE AND RADIATOR ASSY DCA-125USJ - ENGINE AND RADIATOR ASSYPAGE 60 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - ENGINE AND RADIATOR ASSYREMARKS JOHN DEERE 6068TF275ENGINE & RADIATOR ASSY DCA-125USJ - ENGINE AND RADIATOR ASSYPAGE 62 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - ENGINE AND RADIATOR ASSYENGINE & RADIATOR ASSY OUTPUT TERMINAL ASSY DCA-125USJ - OUTPUTTERMINAL ASSYPAGE 64 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - OUTPUTTERMINAL ASSYREMARKS OUTPUT TERMINAL ASSYBATTERY ASSY DCA-125USJ - BATTERY ASSYPAGE 66 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 BATTERY DCA-125USJ - BATTERY ASSYPART NAME REMARKSMUFFLER ASSY DCA-125USJ - MUFFLER ASSYPAGE 68 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - MUFFLER ASSYREMARKS FUEL TANK ASSY DCA-125USJ - FUELTANK ASSYPAGE 70 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - FUELTANK ASSYENCLOSURE #1 ASSY DCA-125USJ - ENCLOSURE #1 ASSYPAGE 72 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - ENCLOSURE #1 ASSYREMARKS PAGE 74 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENCLOSURE #1 ASSYPART NAME DCA-125USJ - ENCLOSURE #1 ASSYREMARKS ENCLOSURE #2 ASSY DCA-125USJ - ENCLOSURE #2 ASSYPAGE 76 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - ENCLOSURE #2 ASSYREMARKS RUBBER SEALS ASSY DCA-125USJ - RUBBER SEALS ASSYPAGE 78 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - RUBBER SEALS ASSYNAMEPLATE AND DECALS ASSY DCA-125USJ - NAMEPLATE AND DECALS ASSYPAGE 80 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - NAMEPLATE AND DECALS ASSYREMARKS DECAL, CONNECTION OF OUTPUT CABLESPECIAL EXPEDITING SERVICE TERMS AND CONDITIONS OF SALE - PARTSPAYMENT TERMS FREIGHT POLICYDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE NOTE PAGEPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERE’S HOW TO GET HELPService Department Warranty Department