Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip DCA125USJ operation manual DCA-125USJ - CONTROL BOX ASSY

Models: DCA125USJ

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DCA-125USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

PAGE 58 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)

Page 58

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Contents

MODEL DCA125USJ OPERATION AND PARTS MANUALPARTS LIST NO. M3870400004 60 Hz GENERATORPAGE 2 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 NOTE PAGE DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGENOTEnumber are subject to change without notice TABLE OF CONTENTSSpecification and part MQ POWER DCA12USJOrdering parts has never been easier PARTS ORDERING PROCEDURESWhen ordering parts, please supply Choose from three easy optionsTable 2. Engine Specifications DCA-125USJ - SPECIFICATIONSTable 1. Generator 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 SYMBOLS DCA-125USJ - SAFETY INFORMATIONSAFETY MESSAGES DANGERGENERATOR SAFETY DCA-125USJ - SAFETY INFORMATIONGENERAL SAFETY ﬁre extinguisherDANGER ENGINE SAFETYDCA-125USJ - SAFETY INFORMATION „ NEVER operate the engine with heat shields or guards removedDCA-125USJ - SAFETY INFORMATION FUEL SAFETYTOWING SAFETY DANGERPower Cord/Cable Safety ELECTRICAL SAFETYGrounding Safety DCA-125USJ - SAFETY INFORMATIONDCA-125USJ - SAFETY INFORMATION BATTERY SAFETYENVIRONMENTAL SAFETY 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 Indoor Installation DCA-125USJ - INSTALLATIONOutdoor Installation CAUTION - EXHAUST HAZARDEngine Operating Panel DCA-125USJ - GENERAL INFORMATIONDCA-125USJ Series Familiarization Generator Generator Control PanelEngine Assembly DCA-125USJ - MAJOR COMPONENTSMuffler Assembly Enclosure AssemblyNOTE PAGE PAGE 20 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11The Control Box is equipped with the following major components DCA-125USJ - GENERATOR CONTROL PANEL Current Transformer  Voltage Selector Switch  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 Panel DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Familiarization The “OutputTerminal Panel ” Figure 8 is provided with the120VAC GFCI Receptacles DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATIONTwist Lock Dual Voltage 120/240 VAC Receptacles Blower Fan Connecting LoadsFigure 13. Connecting Loads Over Current Relay Figure 15. Blower Fan FuseDCA-125USJ - LOAD APPLICATION Single Phase LoadThree Phase Load DANGER - ELECTRICAL SYSTEM HAZARDSVoltage Selector Switch Locking Button Voltage Selector SwitchFigure 16. Voltage Selector Switch DCA-125USJ - GENERATOR OUTPUTSDCA-125USJ - GAUGE READING How to Read the OutputTerminal GaugesFigure 17. Voltage Selector Switch 139VThree Phase Position Reading Amperage3Ø 240/139 Output Terminal Lug Voltages DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output 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 Lubrication Oil DCA-125USJ - PRE-SETUPCircuit Breakers Fuel Checkrefueling Refueling ProcedureWARNING - RESPIRATORY HAZARDS DCA-125USJ - PRE-SETUPTable 12. Anti-Freeze Operating Temperatures Cleaning the RadiatorAir Cleaner WARNING - BURN HAZARDSCAUTION - BATTERY SERVICING SAFETY BatteryBattery Cable Installation WiringCAUTION - LETHAL EXHAUST HAZARD DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALBefore Starting WARNING - STARTINGTHE GENERATORFigure 46. Voltmeter Figure 47. Voltage Adjust Control Knob DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALFigure 50. Coolant Temperature Gauge Figure 45. Frequency Meter HzCAUTION - ENGINE SPEED SWITCH DCA-125USJ - GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE CAUTION - BACKUP GENERATOR USEEmergency Shutdown Procedure DCA-125USJ - GENERATOR SHUT-DOWN PROCEDURENormal Shutdown Procedure Figure 55. MPEC Control Switch Off/ResetService Daily DCA-125USJ - MAINTENANCEAir Cleaner with Dust Indicator General InspectionCheck Oil Level DCA-125USJ - MAINTENANCEAir Removal Replacing Oil Filterbattery charger DCA-125USJ - MAINTENANCEBrakes DCA-125USJ -TRAILER BRAKES MAINTENANCEBrake Adjustment Hydraulic Surge BrakesCAUTION - EYESIGHT HAZARD DCA-125USJ -TRAILER MAINTENANCETires/Wheels/Lug Nuts SuspensionFigure 59. Wheel Lug Nuts Tightening Sequence DCA-125USJ -TRAILER MAINTENANCELug Nut Torque Requirements 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 SYMPTOM DCA-125USJ -TROUBLESHOOTING GENERATORTABLE 18. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMTABLE 19. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-125USJ -TROUBLESHOOTING ENGINE CONTROLLERPAGE 50 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 NOTE PAGE DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGEQTY. Column SAMPLE PARTS LISTDCA-125USJ - EXPLANATION OF CODE IN REMARKS COLUMN NO. ColumnDCA-125USJW/JOHN DEERE 4045TF275 DIESEL ENGINE 1 TO 3 UNITS DCA-125USJ - SUGGESTED SPARE PARTSDescription 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 REMARKS DCA-125USJ - CONTROL BOX ASSYPART NAME FCF-6 45~65HzDCA-125USJ - CONTROL BOX ASSY PAGE 58 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11PART NAME DCA-125USJ - CONTROL BOX ASSYWIRE HARNESS, GENERATOR REMARKSENGINE AND RADIATOR ASSY DCA-125USJ - ENGINE AND RADIATOR ASSYPAGE 60 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 REMARKS DCA-125USJ - ENGINE AND RADIATOR ASSYPART NAME 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 REMARKS DCA-125USJ - OUTPUTTERMINAL ASSYPART NAME OUTPUT TERMINAL ASSYBATTERY ASSY DCA-125USJ - BATTERY ASSYPAGE 66 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 PART NAME DCA-125USJ - BATTERY ASSYBATTERY 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 DCA-125USJ - FUELTANK ASSY PART NAMEENCLOSURE #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 DCA-125USJ - ENCLOSURE #1 ASSY PAGE 74 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11PART 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 DCA-125USJ - RUBBER SEALS ASSY PART NAMENAMEPLATE AND DECALS ASSY DCA-125USJ - NAMEPLATE AND DECALS ASSYPAGE 80 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 REMARKS DCA-125USJ - NAMEPLATE AND DECALS ASSYPART NAME DECAL, CONNECTION OF OUTPUT CABLEPAYMENT TERMS TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE FREIGHT POLICYNOTE PAGE DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGEService Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Warranty Department