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DCA125USJ operation manual DCA-125USJ - ENGINE AND RADIATOR ASSY, Engine & Radiator Assy
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DCA125USJ
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Troubleshooting
Specifications
Install
Parts list
DCA-125USJ -TRAILERWIRING DIAGRAM
Warranty
Dimension
Maintenance
Connecting Loads
MPEC Control Switch Off/Reset
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DCA-125USJ
— ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 62 —
DCA-125USJ
— OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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Image 62
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Contents
MODEL DCA125USJ
OPERATION AND PARTS MANUAL
PARTS LIST NO. M3870400004
60 Hz GENERATOR
PAGE 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 - PAGE
NOTEnumber are subject to change without notice
TABLE OF CONTENTS
Specification and part
MQ POWER DCA12USJ
Ordering parts has never been easier
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Choose from three easy options
Table 2. Engine Specifications
DCA-125USJ - SPECIFICATIONS
Table 1. Generator Specifications
PAGE 6 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
DCA-125USJ - DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
SAFETY SYMBOLS
DCA-125USJ - SAFETY INFORMATION
SAFETY MESSAGES
DANGER
GENERATOR SAFETY
DCA-125USJ - SAFETY INFORMATION
GENERAL SAFETY
fire extinguisher
DANGER
ENGINE SAFETY
DCA-125USJ - SAFETY INFORMATION
NEVER operate the engine with heat shields or guards removed
DCA-125USJ - SAFETY INFORMATION
FUEL SAFETY
TOWING SAFETY
DANGER
Power Cord/Cable Safety
ELECTRICAL SAFETY
Grounding Safety
DCA-125USJ - SAFETY INFORMATION
DCA-125USJ - SAFETY INFORMATION
BATTERY SAFETY
ENVIRONMENTAL SAFETY
DANGER
PAGE 14 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - GENERATOR DECALS
Figure 2. Generator Decals
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
DCA-125USJ - GENERATOR DECALS
Figure 3. Generator Decals Cont
PAGE 16 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - INSTALLATION
Figure 4. Typical Generator Grounding Application
Indoor Installation
DCA-125USJ - INSTALLATION
Outdoor Installation
CAUTION - EXHAUST HAZARD
Engine Operating Panel
DCA-125USJ - GENERAL INFORMATION
DCA-125USJ Series Familiarization Generator
Generator Control Panel
Engine Assembly
DCA-125USJ - MAJOR COMPONENTS
Muffler Assembly
Enclosure Assembly
NOTE PAGE
PAGE 20 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
The 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 Relay
PAGE 22 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
DCA-125USJ - ENGINE OPERATING PANEL
Output Terminal Panel
DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
The “OutputTerminal Panel ” Figure 8 is provided with the
Twist Lock Dual Voltage 120/240 VAC Receptacles
DCA-125USJ - OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Blower Fan
Connecting Loads
Figure 13. Connecting Loads Over Current Relay
Figure 15. Blower Fan Fuse
DCA-125USJ - LOAD APPLICATION
Single Phase Load
Three Phase Load
DANGER - ELECTRICAL SYSTEM HAZARDS
Voltage Selector Switch Locking Button
Voltage Selector Switch
Figure 16. Voltage Selector Switch
DCA-125USJ - GENERATOR OUTPUTS
DCA-125USJ - GAUGE READING
How to Read the OutputTerminal Gauges
Figure 17. Voltage Selector Switch 139VThree Phase Position
Reading Amperage
3Ø 240/139 Output Terminal Lug Voltages
DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V Output Terminal Lug Voltages
1Ø 240V/120V Output Terminal Lug Voltages
DCA-125USJ - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 Output Terminal Lug Voltages
Lubrication Oil
DCA-125USJ - PRE-SETUP
Circuit Breakers
Fuel Check
refueling
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
DCA-125USJ - PRE-SETUP
Table 12. Anti-Freeze Operating Temperatures
Cleaning the Radiator
Air Cleaner
WARNING - BURN HAZARDS
CAUTION - BATTERY SERVICING SAFETY
Battery
Battery Cable Installation
Wiring
CAUTION - LETHAL EXHAUST HAZARD
DCA-125USJ - GENERATOR START-UP PROCEDURE MANUAL
Before Starting
WARNING - STARTINGTHE GENERATOR
Figure 46. Voltmeter Figure 47. Voltage Adjust Control Knob
DCA-125USJ - GENERATOR START-UP PROCEDURE MANUAL
Figure 50. Coolant Temperature Gauge
Figure 45. Frequency Meter Hz
CAUTION - ENGINE SPEED SWITCH
DCA-125USJ - GENERATOR START-UP PROCEDURE AUTO MODE
WARNING - AUTO MODE MAINTENANCE
CAUTION - BACKUP GENERATOR USE
Emergency Shutdown Procedure
DCA-125USJ - GENERATOR SHUT-DOWN PROCEDURE
Normal Shutdown Procedure
Figure 55. MPEC Control Switch Off/Reset
Service Daily
DCA-125USJ - MAINTENANCE
Air Cleaner with Dust Indicator
General Inspection
Check Oil Level
DCA-125USJ - MAINTENANCE
Air Removal
Replacing Oil Filter
battery charger
DCA-125USJ - MAINTENANCE
Brakes
DCA-125USJ -TRAILER BRAKES MAINTENANCE
Brake Adjustment
Hydraulic Surge Brakes
CAUTION - EYESIGHT HAZARD
DCA-125USJ -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Suspension
Figure 59. Wheel Lug Nuts Tightening Sequence
DCA-125USJ -TRAILER MAINTENANCE
Lug Nut Torque Requirements
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
PAGE 46 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ -TRAILERWIRING DIAGRAM
Figure 60. Trailer/Towing Vehicle Wiring Diagram
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
DCA-125USJ - GENERATORWIRING DIAGRAM
Figure 61. Generator Wiring Diagram
PAGE 48 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENGINEWIRING DIAGRAM
Figure 62. Engine Wiring Diagram
SYMPTOM
DCA-125USJ -TROUBLESHOOTING GENERATOR
TABLE 18. GENERATOR TROUBLESHOOTING
POSSIBLE PROBLEM
PAGE 50 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ -TROUBLESHOOTING ENGINE CONTROLLER
TABLE 19. ENGINE CONTROLLER TROUBLESHOOTING MPEC
NOTE PAGE
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
QTY. Column
SAMPLE PARTS LIST
DCA-125USJ - EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
DCA-125USJW/JOHN DEERE 4045TF275 DIESEL ENGINE 1 TO 3 UNITS
DCA-125USJ - SUGGESTED SPARE PARTS
Description
Part number on this Suggested Spare Parts
PAGE 54 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - GENERATOR ASSY
GENERATOR ASSY
REMARKS
DCA-125USJ - GENERATOR ASSY
PART NAME
PAGE 56 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - CONTROL BOX ASSY
CONTROL BOX ASSY
REMARKS
DCA-125USJ - CONTROL BOX ASSY
PART NAME
FCF-6 45~65Hz
DCA-125USJ - CONTROL BOX ASSY
PAGE 58 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
PART NAME
DCA-125USJ - CONTROL BOX ASSY
WIRE HARNESS, GENERATOR
REMARKS
PAGE 60 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
REMARKS
DCA-125USJ - ENGINE AND RADIATOR ASSY
PART NAME
JOHN DEERE 6068TF275
PAGE 62 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENGINE AND RADIATOR ASSY
ENGINE & RADIATOR ASSY
ENGINE & RADIATOR ASSY
DCA-125USJ - ENGINE AND RADIATOR ASSY
PART NAME
PAGE 64 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
REMARKS
DCA-125USJ - OUTPUTTERMINAL ASSY
PART NAME
OUTPUT TERMINAL ASSY
PAGE 66 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - BATTERY ASSY
BATTERY ASSY
PART NAME
DCA-125USJ - BATTERY ASSY
BATTERY
REMARKS
PAGE 68 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - MUFFLER ASSY
MUFFLER ASSY
REMARKS
DCA-125USJ - MUFFLER ASSY
PART NAME
PAGE 70 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - FUELTANK ASSY
FUEL TANK ASSY
DCA-125USJ - FUELTANK ASSY
PART NAME
PAGE 72 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENCLOSURE #1 ASSY
ENCLOSURE #1 ASSY
REMARKS
DCA-125USJ - ENCLOSURE #1 ASSY
PART NAME
DCA-125USJ - ENCLOSURE #1 ASSY
PAGE 74 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
REMARKS
DCA-125USJ - ENCLOSURE #1 ASSY
PART NAME
PAGE 76 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - ENCLOSURE #2 ASSY
ENCLOSURE #2 ASSY
REMARKS
DCA-125USJ - ENCLOSURE #2 ASSY
PART NAME
PAGE 78 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - RUBBER SEALS ASSY
RUBBER SEALS ASSY
DCA-125USJ - RUBBER SEALS ASSY
PART NAME
PAGE 80 - DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11
DCA-125USJ - NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
REMARKS
DCA-125USJ - NAMEPLATE AND DECALS ASSY
PART NAME
DECAL, CONNECTION OF OUTPUT CABLE
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
NOTE PAGE
DCA-125USJ - OPERATION AND PARTS MANUAL - REV. #2 01/27/11 - PAGE
Service Department
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Warranty Department