Multiquip DCA-125SSJU User Manual

OPERATION AND PARTS MANUAL

MQ POWER

DCA-125SSJU

DCA-125SSJU2

PORTABLE

GENERATOR

(STANDARD)

PARTS LIST NO. 3870300064A

S/N7500469 UP TO 7500507-125SSJU

S/N FROM 7500508-125SSJU2

Revision #4 (06/03/03)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046

E-mail:mq@multiquip.com

. PARTS DEPARTMENT:

SERVICE DEPARTMENT:

z www:multiquip.com

PAGE 2 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700 FAX: 800-672-7877 or 310-637-3284

SERVICE DEPARTMENT

800-421-1244 FAX: 310- 537-4259

TECHNICAL ASSISTANCE

800-478-1244 FAX: 310- 631-5032

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: 310- 537-1173

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 3

DCA-125SSJU &DCA-125SSJU &

DCA-125SSJU &

DCA-125SSJU &DCA-125SSJU & DCA-125SSJU2DCA-125SSJU2

DCA-125SSJU2

DCA-125SSJU2DCA-125SSJU2 AC GENERAAC GENERA

AC GENERA

AC GENERAAC GENERA

Here's How To Get Help .................................................... 3

Table Of Contents ............................................................. 4

Parts Ordering Procedures ...............................................5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Installation ................................................................. 14-15

Towing Safety Precaution ...............................................16

Trailer Specifications ................................................. 17-19

Generator Decals ....................................................... 20-21

General Information ........................................................22

Major Components ......................................................... 23

Generator Control Panel ................................................. 24

Engine Operating Panel (up to S/N 7500507) ................. 25

Engine Operating Panel (S/N 7500508~) ................... 26-27

Output Terminal Panel Familiarization ........................ 28-30

Load Application ............................................................. 31

Generator Outputs ..................................................... 32-33

Gauge Reading ............................................................... 33

Output Ter minal Panel Connections ........................... 34-35

Pre Setup .................................................................. 36-40

Generator Start-up Procedure (Manual) ..................... 41-44

Generator Start-up Procedure (Auto Mode) .................... 45

Generator Shut-Down Procedure .................................... 46

Maintenance .............................................................. 47-49

Trailer Brakes Maintenance ............................................ 50

Trailer Maintenance.................................................... 51-52

Trailer Wiring Diagram ..................................................... 53

Generator Wiring Diagram ............................................... 54

Engine Wiring Diagram (Ignition Switch) ......................... 55

Engine Wiring Diagram (w/ Controller) ............................ 56

Engine Troubleshooting .............................................. 58-59

Generator Troubleshooting .............................................. 60

Engine Controller Troubleshooting ................................... 61

Explanation of Code in Remarks Column ....................... 62

Suggested Spare Parts .................................................. 63

TORTOR

TOR

TORTOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Name Plate And Decals ............................................ 64-65

Generator Assembly .................................................. 66-69

Control Box Assembly ............................................... 70-73

Engine & Radiator Assembly..................................... 74-77

Engine Operating Panel Assembly ............................ 78-79

Output Terminal Assembly ......................................... 80-81

Battery Assembly ...................................................... 82-83

Muffler Assembly ...................................................... 84-85

Fuel Tank Assembly .................................................. 86-87

Enclosure Assembly ................................................. 88-91

Rubber Seal Assembly .............................................. 92-93

Terms and Condition of Sale — Parts ............................ 94

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Truck

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

Parts Department

800-427-1244 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Mayco Parts

800-306-2926 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Service Department

800-478-1244 Fax: 310-537-4259

310-537-3700

MQ Power Service Department

800-835-2551 Fax: 310-638-8046

310-537-3700

Warranty Department

800-421-1244, Ext. 279 Fax: 310-537-1173

310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers

800-421-1244 Fax: 310-537-3927

310-537-3700

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE POST OFFICE BOX 6254 CARSON, CALIFORNIA 90749 310-537-3700 • 800-421-1244 FAX: 310-537-3927 E-MAIL: mq@multiquip.com WWW: multiquip.com

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

DCA-125SSJU SERIES — SPECIFICATIONS

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PAGE 6 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — DIMENSIONS

Figure 1. Dimensions

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 7

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been

NOTE

Before using this GENERATOR, ensure that the operating individual has read and understands all instructions in this manual.

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA125SSJU Series WHISPERWATT™ GENERATOR.

HAZARD SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

NEVER operate this equipment in a confined area or enclosed structure that does not

provide ample free flow air.

Explosive Fuel

Diesel fuel is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or

sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent.

DANGER: You WILL be KILLED or

SERIOUSLY injured if you DO NOT follow directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you DO NOT follow directions.

CAUTION: You CAN be injured if you

DO NOT follow directions.

Potential hazards associated with trowel operation will be referenced with " this manual, and will be referenced in conjunction with Safety "

Message Alert Symbols

Hazard Symbols

" which appear throughout

Burn Hazards

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep and

clothing

prevent injury.

fingers, hands, hair

away from all moving parts to

PAGE 8 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF

switch in the OFF position, when the trowel is not in use.

Over Speed Conditions

NEVER tamper with the factory settings of the

engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

This

NOTE

the surrounding environment could be damaged if you do not follow instructions.

generator

, other property, or

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual to help prevent damage to your trowel, other property, or the surrounding environment.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 9

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

The following safety guidelines should always be used when operating the DCA-125SSJU Series Generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot!

can cause serious burns.

■

The engine of this generator requires an adequate free flow of

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed boots and other protective devices required by the job.

cooling air. operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

■

ALWAYS make sure generator is properly grounded.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

NEVER use gas piping as an electrical ground.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

components

NEVER

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

ALWAYS check the machine for loosened threads or bolts before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

PAGE 10 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

bodily harm or even death.

ALWAYS make sure generator installation is accordance with

national and local electrical codes

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

NEVER power cables or cords

■

NEVER is being transfer to a load.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job See Table 5.

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. performing maintenance on the generator.

stand in water

while AC power from the generator

Turn all circuit breakers OFF before

lay in wate

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

■

ALWAYS make sure that electrical circuits are properly

grounded

codes before operating generator. Severe electrocution can result from operating an ungrounded generator.

■

ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using generator.

■

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

■

ALWAYS read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

DANGERDANGER

DANGER

DANGERDANGER

securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DANGERDANGER

DANGER

DANGERDANGER

DANGER

DANGERDANGER

per the

National Electrical Code

(NEC) and local

injury

death!

Never use damaged or worn cables when

connecting equipment to the generator.

Make sure power connecting cables are

WET

HANDS

NEVER grab or

touch a live

power cord with wet hands , the possibility exists

of electrical shock, electrocution, and even

death!

POWER

CORD

(POWER ON)

DANGERDANGER

DANGER

DANGERDANGER

■

Backfeed to a utility system can cause property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the engine

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

Maintenance Safety

■

electrocution

and or

DO NOT touch or open any of the below

mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

■

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the “OFF” position when contact with the output terminals is required. There exists the possibility of

which can cause severe bodily harm or even death

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 11

electrocution, electrical shock or burn,

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

■

NEVER Run engine without air filter. Severe engine damage may occur.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

■

ALWAYS disconnect the performing service on the generator.

■

ALWAYS be sure the operator is familiar with proper safety precautions when operating the generator set.

■

ALWAYS store equipment properly when not in use.

■

DO NOT leave the generator running in the unattended.

■

DO NOT allow unauthorized people to operate this equipment.

■

ALWAYS read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

■

Refer to the technical questions or information.

DANGER:DANGER:

DANGER:

DANGER:DANGER:

John Deere Engine Manual

negative battery terminal

manual mode

for engine

before

Battery

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

3. ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

always

wear safety glasses.

Pay close attention to ventilation when operating the generator inside

tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the UVWO output terminals.

National Electrical Code

4. ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

5. ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

Transporting

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See next page “ basic towing techniques.

clothing or skin

Towing Safety Precautions

, rinse skin or clothing

” for

PAGE 12 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Conform to

(DOT) towing generator.

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR) of 6,000 lbs.

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

Department of Transportation

Safety Towing Regulations

before

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

DOT Requirements include the following:

z z

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

fire extinguisher

first aid kit

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

The maximum speed for highway towing is 45 MPH unless posted otherwise. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

Trailer tires should be inflated to 50 psi cold.

chock blocks

underneath wheel to prevent rolling,

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

always

know the location of the

keep a phone on the job site

and

fire department

. This

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 13

DCA-125SSJU SERIES — INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground. a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect the

ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried aminimum of 8 ft. into the ground.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 15

DCA-125SSJU SERIES — TOWING SAFTEY PRECAUTIONS

■

Towing Safety Precautions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 4) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

Check with your local county or state safety towing regulations before towing your

generator.

ALWAYS attach trailer’s safety chain to bumper of towing vehicle.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place rolling, while parked.

■

Place prevent tipping, while parked.

■

Use the trailer’s hand winch to adjust the height of the trailer, then insert locking pin to lock wheel stand in place, while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 3. Generator with Trailer

PAGE 16 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Explanation of Chart:

This section is to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions when reading Table 2.

ALWAYS make sure the trailer is in good

operating condition. Check the tires for proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

5. Frame Length - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 17 and Figure 67 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 17

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

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X05-RLRT 52-ACDONONSBL0072"421"55.BL008

FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

W07-RLRT ,06-,54-ACD

X07-RLRT ,06-,54-ACD

FX07-RLRT ,06-,54-ACD

FX001-RLRT 521,001-ACDLAG051CILUARDYH

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002CILUARDYH

FX022-RLRT 022-ACDLAG052CILUARDYH

FX003-RLRT 003-ACDLAG052CILUARDYH

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

LLEC

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

ONEGRUSSBL0007"681"77.BL0002

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DAPTALF

PAGE 18 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

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W01-RLRT SSALCLLAB"2

01-RLRT SSALCLLAB"2

FX01-RLRT SSALCLLAB"2

W522-RLRT SSALCLLAB"2

WLB-RLRT

004

X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

W07-RLRT SSALCLLAB"2

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FX07-RLRT SSALCLLAB"2

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C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

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C41-502

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521/58-RLRT -2ELBATSUJDA

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FX051-RLRT EYELLAB"3E61-057

FX022-RLRT EYE"3

ELBATSUJDA

FX003-RLRT EYE"3

ELBATSUJDA

FX004-RLRT EYE"3

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FX006-RLRT LEEHWHT5H5.71R57/512TS

RA008-RLRT LEEHWHT5H5.71R57/512TS

D51R57/522TS

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)4(SAIB

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DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 19

DCA-125SSJU SERIES — GENERATOR DECALS

The DCA-125SSJU Series generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 20 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR DECALS

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 21

DCA-125SSJU SERIES — GENERAL INFORMATION

DCA-125SSJU Series Familiarization Generator

The MQ Power DCA-125SSJU Series is a 100 kW (Figure 4) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Throttle Handle (Up to S/N 77500507)

Fuel Level Gauge

Engine Speed Switch (S/N 7500508~)

Cold Starting Button

Panel Light

Panel Light Switch

Ignition/Preheat Switch ( Up to S/N 77500507)

Auto ON/OFF Engine Controller (S/N 7500508~)

Generator Control Panel

The “Generator Control Panel” is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

Over-Current Relay

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

Three 250 VAC output receptacles (CS-6369), 50 amps

Three auxiliary circuit breakers, 250V @50 amps

Two 125 VAC output receptacles, (GFCI), 20 amps

Two GFCI circuit breakers, 120V@ 20amps

Five output terminal lugs (3Ø power)

Control Box

The “Control Box” is provided with the following:

3-Pole, 300 amp Main Circuit Breaker

Automatic Voltage Regulator

Current Transformer

Emergency Relay

generator

Open Delta Excitation System

The DCA-125SSJU Series Generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase ot provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load.

Engine

The DCA-125SSJU Series Generator is powered by a 4 cycle, water cooled, turbocharged

Model

6068TF250 meet every performance requirement for the generator. Reference Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±.5%. The electronic governor option increases frequency variation to ±0.25%.

Extension Cables

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 5) as a guide for selecting proper extension cable size.

Open-Delta

" excitation system. The open delta

Diesel

fixed ceiling

" and responds

John Deere

engine. This engine is designed to

PAGE 22 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — MAJOR COMPONENTS

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DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 23

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DCA-125SSJU SERIES — GENERATOR CONTROL PANEL

Figure 5. Generator Control Panel

The definitions below describe the controls and functions of the DCA-125SSJU Series " (Figure 5).

1. Main Circuit Breaker – This three-pole, 300 amp main breaker is provided to protect the UVWO output terminals from overload.

2. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

4. Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

5. Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

6. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the output voltage present at the UVWO terminals.

PAGE 24 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

Generator Control Panel

Located behind the generator control panel is the

Control Box

electronic components required to make the genertator function.

The “Control Box” is equipped with the following major components:

Over-Current Relay

Voltage Rectifer

Starter Relay

Engine Controller (Computer Controlled)

Current Transformer

Voltage Selector Switch

NOTE

To restore power to the UWVO output terminals, press the

reset

button on the overcurrent relay and place the

circuit breaker in the

. This box contains some of the necessary

Remember the

relay

monitors the current flowing from the UWVO output terminals to the load.

In the event of a short circuit or over current condition, it will automatically trip the main 250 amp breaker.

closed

position (ON).

Generator

overcurrent

main

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

Figure 6. Engine Operating Panel Up To

The definitions below describe the controls and functions of the DCA-125SSJU Series " (Figure 6), up to S/N 7500507.

1. Panel Light – Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control panel light.

3. Oil Pressure Gauge – During normal operation this gauge be should read in the “GREEN” zone. When starting the generator the oil pressure may read a little bit higher, but after the engine warms up the oil pressure should return to the green zone.

4. Water Temperature Gauge – During normal operation this gauge be should read in the “GREEN” zone.

5. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

Engine Operating Panel

S/N 7500507

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

8. Engine Speed Throttle- This lever controls the speed

9. Ignition Switch – Turns the engine on, off or to preheat

10. Cold Starting Button – Used to warm the engine glow

11. Water Temperature Warning Light - Indicates if the

12. Oil Pressure Warning Light - This will indicate if the

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

of the engine (low or high).

the engine.

plugs in cold weather conditions. Press and hold the engine cold starting button until the button illuminates.

coolant is low. This warning will shut off the engine.

oil pressure is too low or high. This warning will shut off the engine.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 25

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel From

PAGE 26 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

S/N 7500508

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-125SSJU2 " from S/N 7500508 ~.

2. Panel Light Switch – When activated will turn on control panel light.

3. Oil Pressure Gauge – During normal operation this gauge be should read between 42 to 71 psi. When starting the generator the oil pressure mar read a little bit higher, but after the engine warms up the oil pressure should return to the green zone.

4. Water Temperature Gauge – During normal operation this gauge be should read between 165

5. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8. Engine Speed Switch - This switch controls the speed of the engine (low or high).

9. Cold Starting Button – Used to warm the engine glow plugs in cold weather conditions. Press and hold the engine cold starting button until the button illuminates.

10. Auto On/Off Engine Controller – This controller

has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault), has been detected. When a fault has been detected the engine controller will evaluate the fault. Any

major

controller to shutdown the generator.

Engine Operating Panel

fault will cause the

" (Figure 7)

and 203oF.

During engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s " Over Crank Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the "

Also the engine controller will shutdown the generator in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

A. Off/Manual/Auto Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has

E. Overspeed Shutdown – Indicates the engine is

F. Engine Running – Indicates that engine is running

cranking cycle

running of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the immediately.

If the generator is to be connected to a building's AC power source via a transfer switch (isolation), place the switch in the generator will monitor the AC line output from the building's power source.

has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

temperature has exceeded 215°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a fault.

running at an unsafe speed. This is considered a fault.

at a safe operating speed.

, The MPEC will attempt to crank the

Over Speed Protection

manual

position, the generator will start

auto

position. In this position the

" mode.

major

fault.

major

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 27

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “

Output Terminal Panel

the following:

Three (3) 240V Output Receptacles, 50 amp

Three (3) Circuit Breakers 240V @50 amps

Two (2) 120V GFCI receptacles, 20 amp

Two (2) GFCI Circuit Breakers 120V@ 20 amps

One 300 Amp Main Circuit Breaker

Five (5) Output Terminal Lugs

” (Figure 8) is provided with

Output Terminal Panel

The

Output Terminal Panel

located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

( Figure 8) shown below is

Terminal legs “O” and “Ground” are considered

bonded grounds

Figure 8. Output Terminal Panel

PAGE 28 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the UVWO terminals.

Pressing the being tripped. Pressing the " the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

" (See Figure 9) in

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the UVWO terminals.

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face plate cover (Figure 12). Un-lock the locking latch, and lift the terminal cover to gain access to the plastic face plate. Remove the screws securing the face plate to the terminal enclosure, then lift the plastic hinged face plate.

voltage regulator control knob

Figure 11. Voltage Regulator Control Knob

increase

the voltage, turning the knob counter-

decrease

(Figure 11) on the

the voltage.

After the load wires have been securely attached to the UVWO terminals, reinstall the plastic face plate. Place the

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240 VAC, 50 amp auxiliary twist-lock (CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can when the voltage selector switch is placed in the

only

be accessed

single-

terminal cover in the down position and secure the locking latch.

phase 240/120 position.

Figure 12. Plastic Face Plate (UVWO Terminals)

Figure 10. 240 VAC Twist-Lock

Auxiliary Receptacles

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 29

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