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Multiquip DCA125USJ operation manual DCA-125USJ - CONTROL BOX ASSY, Part Name, Remarks, Replaces

Models: DCA125USJ

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DCA-125USJ — CONTROL BOX ASSY.

DCA-125USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.
NO.	PART NO.	PART NAME	QTY.	REMARKS
31	0601840073	RHEOSTAT (VOLTAGE REGULATOR)	............... 1	RA20A2SE102BJ 2W 1k OHM
32	0601840121	KNOB	1
33	ECU9988NJD	CONTROLLER	1	REPLACES 0602202593
34	0601831340	SWITCH	1	7562K4
35	0027104040	MACHINE SCREW	2
35A	0207004000	HEX, NUT	2
36	0602103092	PREHEAT LAMP	1	PL-05
36A	0601810245	BULB	1
37	0602120096	TACHOMETER	1	111812
38	0602122093	OIL PRESSURE GAUGE	1	100174
39	0602123092	WATER TEMPERATURE GAUGE	1	100182
40	0602121080	CHARGING AMMETER	1	100158
41	0602125090	FUEL GAUGE	1	100176
42	0601810141	PANEL LIGHT	1	8826800370
43	0601831330	SWITCH, PANEL LIGHT	1	90-0001
44	M1223100004	STOPPER	1
45	M3223100004	STOPPER	1
46	0027105010	MACHINE SCREW	4
47	0027105010	MACHINE SCREW	4
48	M9220100004	SET SCREW	2
49	0080200007	SNAP RING	2
50	0602202592	STARTER RELAY	1	AT141011
51	0027106018	MACHINE SCREW	2
52	LY2DDC12V	RELAY	1
52A	PTF08A	BASE	1
52B	PYCA1	CLIP	2
53	0027104020	MACHINE SCREW	2
54	0601823240	RECTIFIER	1	DE4503
57	0602122272	UNIT, OIL PRESSURE	1	108497
57A	M9200100004	ADAPTOR	1
58	0602123261	UNIT, WATER TEMPERATURE	1	02025-00
58A	0602021109	PACKING	1
60	M3246701904	WIRE HARNESS, GENERATOR	1
61	M3357201102	WIRE HARNESS, ENGINE	1
62	M3357200304	WIRE HARNESS, FUEL LEAK	1	8400041~
63	0601802149	FUSE	2	F-106510A
64	0601823240	RECTIFIER	1	DE4503
65	0602103092	ALARM LAMP, PL095	1	8400041~
65A	0601810245	BULB	1	8400041~

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 59

Image 59

Multiquip DCA125USJ operation manual DCA-125USJ - CONTROL BOX ASSY, Part Name, Remarks, Replaces, Wire Harness, Generator

Contents

60 Hz GENERATOR OPERATION AND PARTS MANUALPARTS LIST NO. M3870400004 MODEL DCA125USJPAGE 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 PAGEMQ POWER DCA12USJ TABLE OF CONTENTSSpecification and part NOTEnumber are subject to change without noticeChoose from three easy options PARTS ORDERING PROCEDURESWhen ordering parts, please supply Ordering parts has never been easierPAGE 6 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - SPECIFICATIONSTable 1. Generator Specifications Table 2. Engine SpecificationsDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE DCA-125USJ - DIMENSIONS TOP, SIDE AND FRONTFigure 1. Dimensions DANGER DCA-125USJ - SAFETY INFORMATIONSAFETY MESSAGES SAFETY SYMBOLSﬁre extinguisher DCA-125USJ - SAFETY INFORMATIONGENERAL SAFETY GENERATOR SAFETY„ NEVER operate the engine with heat shields or guards removed ENGINE SAFETYDCA-125USJ - SAFETY INFORMATION DANGERDANGER FUEL SAFETYTOWING SAFETY DCA-125USJ - SAFETY INFORMATIONDCA-125USJ - SAFETY INFORMATION ELECTRICAL SAFETYGrounding Safety Power Cord/Cable SafetyDANGER BATTERY SAFETYENVIRONMENTAL SAFETY DCA-125USJ - SAFETY INFORMATIONPAGE 14 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - GENERATOR DECALSFigure 2. Generator Decals DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE DCA-125USJ - GENERATOR DECALSFigure 3. Generator Decals Cont PAGE 16 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - INSTALLATIONFigure 4. Typical Generator Grounding Application CAUTION - EXHAUST HAZARD DCA-125USJ - INSTALLATIONOutdoor Installation Indoor InstallationGenerator Control Panel DCA-125USJ - GENERAL INFORMATIONDCA-125USJ Series Familiarization Generator Engine Operating PanelEnclosure Assembly DCA-125USJ - MAJOR COMPONENTSMuffler Assembly Engine AssemblyPAGE 20 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 NOTE PAGE Over-Current Relay  Voltage Rectifer AVR  Starter Relay DCA-125USJ - GENERATOR CONTROL PANEL Current Transformer  Voltage Selector Switch The Control Box is equipped with the following major componentsPAGE 22 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENGINE OPERATING PANELFigure 7. Engine Operating Panel DCA-125USJ - ENGINE OPERATING PANEL The “OutputTerminal Panel ” Figure 8 is provided with the DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Familiarization Output Terminal PanelTwist Lock Dual Voltage 120/240 VAC Receptacles DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATION120VAC GFCI Receptacles Figure 15. Blower Fan Fuse Connecting LoadsFigure 13. Connecting Loads Over Current Relay Blower FanDANGER - ELECTRICAL SYSTEM HAZARDS Single Phase LoadThree Phase Load DCA-125USJ - LOAD APPLICATIONDCA-125USJ - GENERATOR OUTPUTS Voltage Selector SwitchFigure 16. Voltage Selector Switch Voltage Selector Switch Locking ButtonReading Amperage How to Read the OutputTerminal GaugesFigure 17. Voltage Selector Switch 139VThree Phase Position DCA-125USJ - GAUGE READING3Ø 208V/1Ø120V Output Terminal Lug Voltages DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 3Ø 240/139 Output Terminal Lug Voltages1Ø 240V/120V Output Terminal Lug Voltages DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONS3Ø 480/277 Output Terminal Lug Voltages Fuel Check DCA-125USJ - PRE-SETUPCircuit Breakers Lubrication OilDCA-125USJ - PRE-SETUP Refueling ProcedureWARNING - RESPIRATORY HAZARDS refuelingWARNING - BURN HAZARDS Cleaning the RadiatorAir Cleaner Table 12. Anti-Freeze Operating TemperaturesWiring BatteryBattery Cable Installation CAUTION - BATTERY SERVICING SAFETYWARNING - STARTINGTHE GENERATOR DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALBefore Starting CAUTION - LETHAL EXHAUST HAZARDFigure 45. Frequency Meter Hz DCA-125USJ - GENERATOR START-UP PROCEDURE MANUALFigure 50. Coolant Temperature Gauge Figure 46. Voltmeter Figure 47. Voltage Adjust Control KnobCAUTION - BACKUP GENERATOR USE DCA-125USJ - GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE CAUTION - ENGINE SPEED SWITCHFigure 55. MPEC Control Switch Off/Reset DCA-125USJ - GENERATOR SHUT-DOWN PROCEDURENormal Shutdown Procedure Emergency Shutdown ProcedureGeneral Inspection DCA-125USJ - MAINTENANCEAir Cleaner with Dust Indicator Service DailyReplacing Oil Filter DCA-125USJ - MAINTENANCEAir Removal Check Oil LevelDCA-125USJ - MAINTENANCE battery chargerHydraulic Surge Brakes DCA-125USJ -TRAILER BRAKES MAINTENANCEBrake Adjustment BrakesSuspension DCA-125USJ -TRAILER MAINTENANCETires/Wheels/Lug Nuts CAUTION - EYESIGHT HAZARDDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE DCA-125USJ -TRAILER MAINTENANCELug Nut Torque Requirements Figure 59. Wheel Lug Nuts Tightening SequencePAGE 46 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ -TRAILERWIRING DIAGRAMFigure 60. Trailer/Towing Vehicle Wiring Diagram DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE DCA-125USJ - GENERATORWIRING DIAGRAMFigure 61. Generator Wiring Diagram PAGE 48 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENGINEWIRING DIAGRAMFigure 62. Engine Wiring Diagram POSSIBLE PROBLEM DCA-125USJ -TROUBLESHOOTING GENERATORTABLE 18. GENERATOR TROUBLESHOOTING SYMPTOMPAGE 50 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ -TROUBLESHOOTING ENGINE CONTROLLERTABLE 19. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE NOTE PAGENO. Column SAMPLE PARTS LISTDCA-125USJ - EXPLANATION OF CODE IN REMARKS COLUMN QTY. ColumnPart number on this Suggested Spare Parts DCA-125USJ - SUGGESTED SPARE PARTSDescription DCA-125USJW/JOHN DEERE 4045TF275 DIESEL ENGINE 1 TO 3 UNITSPAGE 54 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - GENERATOR ASSYGENERATOR ASSY REMARKS DCA-125USJ - GENERATOR ASSYPART NAME PAGE 56 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - CONTROL BOX ASSYCONTROL BOX ASSY FCF-6 45~65Hz DCA-125USJ - CONTROL BOX ASSYPART NAME REMARKSPAGE 58 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - CONTROL BOX ASSYREMARKS DCA-125USJ - CONTROL BOX ASSYWIRE HARNESS, GENERATOR PART NAMEPAGE 60 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENGINE AND RADIATOR ASSYENGINE AND RADIATOR ASSY JOHN DEERE 6068TF275 DCA-125USJ - ENGINE AND RADIATOR ASSYPART NAME REMARKSPAGE 62 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENGINE AND RADIATOR ASSYENGINE & RADIATOR ASSY ENGINE & RADIATOR ASSY DCA-125USJ - ENGINE AND RADIATOR ASSYPART NAME PAGE 64 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - OUTPUTTERMINAL ASSYOUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY DCA-125USJ - OUTPUTTERMINAL ASSYPART NAME REMARKSPAGE 66 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - BATTERY ASSYBATTERY ASSY REMARKS DCA-125USJ - BATTERY ASSYBATTERY PART NAMEPAGE 68 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - MUFFLER ASSYMUFFLER ASSY REMARKS DCA-125USJ - MUFFLER ASSYPART NAME PAGE 70 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - FUELTANK ASSYFUEL TANK ASSY PART NAME DCA-125USJ - FUELTANK ASSYPAGE 72 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENCLOSURE #1 ASSYENCLOSURE #1 ASSY REMARKS DCA-125USJ - ENCLOSURE #1 ASSYPART NAME PAGE 74 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENCLOSURE #1 ASSYREMARKS DCA-125USJ - ENCLOSURE #1 ASSYPART NAME PAGE 76 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - ENCLOSURE #2 ASSYENCLOSURE #2 ASSY REMARKS DCA-125USJ - ENCLOSURE #2 ASSYPART NAME PAGE 78 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - RUBBER SEALS ASSYRUBBER SEALS ASSY PART NAME DCA-125USJ - RUBBER SEALS ASSYPAGE 80 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 DCA-125USJ - NAMEPLATE AND DECALS ASSYNAMEPLATE AND DECALS ASSY DECAL, CONNECTION OF OUTPUT CABLE DCA-125USJ - NAMEPLATE AND DECALS ASSYPART NAME REMARKSFREIGHT POLICY TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSDCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE NOTE PAGEWarranty Department HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Service Department