Multiquip DCA125USJ User Manual
PARTS AND OPERATION MANUAL
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 ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PAGE 2 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
NOTE PAGE
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 3
TABLE OF CONTENTS
MQ POWER DCA12USJMQ POWER DCA12USJ
MQ POWER DCA12USJ
MQ POWER DCA12USJMQ POWER DCA12USJ
AC GENERAAC GENERA
AC GENERA
AC GENERAAC GENERA
California Proposition 65 Warning ..................................... 2
Here's How To Get Help ....................................................3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ............................................... 5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) .......................................... 7
Safety Information ....................................................... 8-13
Generator Decals....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 21
Engine Operating Panel ............................................. 22-23
Output Terminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
Output Terminal Panel Connections ........................... 30-31
Pre Setup .................................................................. 32-35
Generator Start-up Procedure (Manual) ..................... 36-37
Generator Start-up Procedure (Auto Mode) .................... 38
Generator Shut-Down Procedure .................................... 39
Maintenance .............................................................. 40-42
Trailer Brakes Maintenance ............................................ 43
Trailer Maintenance .................................................... 44-45
Trailer Wiring Diagram ..................................................... 46
Generator Wiring Diagram ............................................... 47
Engine Wiring Diagram ................................................... 48
Generator Troubleshooting .............................................. 49
Engine Controller Troubleshooting ................................... 50
Explanation of Code in Remarks Column ....................... 52
Suggested Spare Parts .................................................. 53
TORTOR
TOR
TORTOR
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly .................................................. 54-55
Control Box Assembly ............................................... 56-59
Engine & Radiator Assembly ..................................... 60-63
Output Terminal Assembly ......................................... 64-65
Battery Assembly ...................................................... 66-67
Muffler Assembly ...................................................... 68-69
Fuel Tank Assembly .................................................. 70-71
Enclosure #1 Assembly ............................................ 72-75
Enclosure #2 Assembly ............................................ 76-77
Rubber Seals Assembly ............................................ 78-79
Nameplate and Decals .............................................. 80-81
Terms and Condition of Sale — Parts ............................ 82
Specification and part
NOTE
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
PARTS ORDERING PROCEDURES
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Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
To obtain an MQ Account, contact you
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
❒ 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
www.multiquip.com
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 5
When ordering parts, please supply:
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Tr uck
■ Ground
■ Next Day
■ Second/Third Day
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
1
DCA-125USJ — SPECIFICATIONS
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PAGE 6 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 7
1
DCA-125USJ — SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. 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.
SAFETY MESSAGES
The four 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 four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 8 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — SAFETY INFORMATION
.
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the influence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fire could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 9
DCA-125USJ — SAFETY INFORMATION
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ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filte
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
PAGE 10 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
ALWAYS use extreme caution when working with
flammable liquids.
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 appropriate containers, in well-ventilated
areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order 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 mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
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. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
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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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
LEPOWERCABLESINCABLETRAYWITHTIE
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 11
DCA-125USJ — SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 12 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open flames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
DO NOT use food or plastic containers to
dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 13
DCA-125USJ — GENERATOR DECALS
The DCA-125USJ generator is equipped with a number of safety decals (Figures 2 and 3). 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.
Figure 2. Generator Decals
PAGE 14 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — GENERATOR DECALS
Figure 3. Generator Decals (Cont.)
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 15
1
DCA-125USJ — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 16 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — 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.
CAUTION - EXHAUST HAZARD
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.
Indoor Installation
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.
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.
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 17
DCA-125USJ — GENERAL INFORMATION
DCA-125USJ Series Familiarization
Generator
The MQ Power Model DCA-125USJ is a 100 kW
(Figure 5) 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
Fuel Level Gauge
Pre-heat Lamp
Panel Light/Panel Light Switch
Auto ON/OFF Engine Controller (MPEC)
Fuel Leak Detected Alarm Lamp
Generator Control Panel
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 300 amp Main Circuit Breaker
Control Box
The “Control Box”, located behind the
Panel
, is provided with the following:
Automatic Voltage Regulator
Current Transformer
Over-Current Relay
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
Voltage Selector Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxilliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
Battery Charger (Optional)
Water Heater (Optional)
Generator Control
generator
Open Delta Excitation System
The DCA-125USJ 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 to 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-125USJ is powered by a 4 cycle, water cooled,
direct injection, turbocharged JOHN DEERE
6068TF275 Diesel Engine
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.
Electric Governor System
The electric governor system controls the RPMs of the
engine. When the engine demand increases or decreases,
the governor system regulates the frequency variation to
±.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
fixed ceiling
" and responds
Model
. This engine is designed to meet
PAGE 18 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — MAJOR COMPONENTS
Figure 5. Major Components
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DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 19
NOTE PAGE
PAGE 20 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
Figure 6. Generator Control Panel
DCA-125USJ — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-125USJ
1. Main Circuit Breaker – This three-pole, 300A main
breaker is provided to protect the the
Terminal Lugs
2. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
3. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
4. 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.
5. AC Voltmeter – Indicates the output voltage present at
the
U,V, and W Output Terminal Lugs
6. 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.
Generator Control Panel
(Figure 6).
U,V, and W Output
from overload.
.
Located behind the generator control panel is the
Control Box
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
Over-Current Relay
Voltage Rectifer (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
NOTE
In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.
To restore power to the
reset
button on the overcurrent relay and place the
circuit breaker in the
Generator
. This box contains some of the necessary
Remember the
relay
monitors the current
flowing from the
Output Terminal Lugs
load.
Output Terminal Panel
overcurrent
U,V, and W
to the
, press the
main
closed
position (ON).
7. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 21
1
DCA-125USJ — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
PAGE 22 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-125USJ
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 between 35 to 65 psi. When
starting the generator the oil pressure may read a little
higher, but after the engine warms up the oil pressure
should return to the correct pressure range.
4. Water Temperature Gauge – During normal operation
this gauge be should read between 180° and 221°F.
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. Pre-Heat Lamp – As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine.
When the lamp turns off, the engine has been preheated
and will start automatically.
9. Fuel Leak Detected Alarm Lamp – This lamp will
illuminate when a leak in the fuel tank containment
enclosure is detected.
10. Auto On/Off Engine Controller (MPEC) –
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
and all major faults will
shutdown the generator.
Engine Operating Panel
(Figure 7).
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
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 shut down the engine 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. MPEC Control Switch – This switch controls the
B. Low Oil Pressure – Indicates the engine pressure has
C. High Coolant Temperature – Indicates the engine
D. Overcrank Shutdown – Indicates the unit has
E. Overspeed Shutdown – Indicates the engine is running
F. Engine Running – Indicates that engine is running at
cranking cycle
Over Speed Protection
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start 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 AUTO position. In this position the
generator will monitor the AC line output from the
building's power source.
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 239F. 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.
at an unsafe speed. This is considered a
a safe operating speed.
fault.
, The MPEC will attempt to crank the
Over Crank Protection
mode.
major
fault.
major
major
fault.
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 23
DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The
Output Terminal Panel
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 located
Terminal legs “O” and “Ground” are
considered
bonded grounds
Output Terminal Familiarization
The “
Output Terminal Panel
following:
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
.
Two (2) GFCI Circuit Breakers @ 20 amps
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
” (Figure 8) is provided with the
Figure 8. Output Terminal Panel
PAGE 24 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
DCA-125USJ — 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 auxilliary 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
Output Terminal Lugs
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Figure 11. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire Hookup Panel)
The
Output Terminal Lugs
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
.
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
are protected by a plastic face
(Figure 11) on the
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxilliary 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-
phase 240/120 position.
Figure 12. Plastic Face Plate (Output Terminal Lugs)
Figure 10. 120/240V Twist-Lock
Auxiliary Receptacles
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 25
1
DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the
Lugs
or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the output terminals from overload, a
main
3-pole, 300A
switch ALL circuit breakers to the OFF position prior to
starting the engine.
circuit breaker is provided. Make sure to
Ouput Terminal
Blower Fan
This unit has an intake fan located at the rear of the machine
to draw outside air into the cabinet to cool the engine. The
fan has a 10 amp AC fuse located beneath the
Selector Switch
CAUTION - ELECTRICAL SHOCK HAZARD
Voltage
(Figure 15).
Figure 15. Blower Fan Fuse
Figure 13. Connecting Loads
Over Current Relay
An
over current relay
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
rent relay must be pressed. The over current relay is located in the control box.
(Figure 14) is connected to the main
reset button
on the over cur-
The blower fan fuse has current running
through it any time the engine is
operating. This fuse IS NOT connected
to the main circuit breaker of the
generator. Attempting to replace the fuse
with the engine and/or generator
operating could result in
harm
. ALWAYS turn the unit completely off before
attempting to replace or handle the fuse.
electrocution
and
severe bodily
Figure 14. Over Current Relay
PAGE 26 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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