Multiquip DCA125USJ User Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

SERIES

MODEL DCA-125USJ

50 Hz GENERATOR

PARTS LIST NO. M3870400004

Revision #0 (03/11/05)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-631-5032

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-125USJ (50 HZ)Ultra Silent Generator

. Multiquip Inc. reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — 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 Message Alert Symbols .................................... 8-9

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

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

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

Trailer Specifications ...................................................... 17

Generator Decals....................................................... 18-19

General Information ........................................................ 20

Major Components ......................................................... 21

Generator Control Panel ................................................. 23

Engine Operating Panel ............................................. 24-25

Output Terminal Panel Familiarization ........................ 26-28

Load Application ............................................................. 29

Generator Outputs ..................................................... 30-31

Gauge Reading ............................................................... 31

Output Terminal Panel Connections ........................... 32-33

Pre Setup .................................................................. 34-37

Generator Start-up Procedure (Manual) ..................... 38-40

Generator Start-up Procedure (Auto Mode) .................... 41

Generator Shut-Down Procedure .................................... 42

Maintenance .............................................................. 43-45

Trailer Brakes Maintenance ............................................ 46

Trailer Maintenance .................................................... 47-48

Trailer Wiring Diagram ..................................................... 49

Generator Wiring Diagram ............................................... 50

Engine Wiring Diagram ................................................... 51

Generator Troubleshooting .............................................. 52

Engine Controller Troubleshooting ................................... 53

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

TORTOR

TOR

TORTOR

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 56-57

Control Box Assembly ............................................... 58-61

Engine & Radiator Assembly..................................... 62-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure #1 Assembly ............................................ 74-77

Enclosure #2 Assembly ............................................ 78-79

Rubber Seals Assembly ............................................ 80-81

Nameplate and Decals .............................................. 82-83

Terms and Condition of Sale — Parts ............................ 84

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

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 ✓ Tr u c k

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.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-631-5032

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

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. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-125USJ (50 HZ)— SPECIFICATIONS

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PAGE 6 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 7

DCA-125USJ (50 HZ) — 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

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

Model DCA-125USJ

HAZARD SYMBOLS

(50 HZ)ULTRA-SILENT™

GENERATOR.

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

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-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ) — 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.

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.

NOTE

This

generator

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

, other property, or

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 9

DCA-125USJ (50 HZ) — RULES FOR SAFE OPERATION

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

The following safety guidelines should always be used when operating the DCA-125USJ (50 HZ)Generator:

GENERAL SAFETY

■

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

■

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.

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

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

■

The engine of this

hot!

generator requires an adequate free flow of cooling air.

■

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.

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.

components can cause serious burns.

NEVER

■

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

■

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

bodily harm or even death.

■

ALWAYS make sure generator is properly grounded. NEVER use gas piping as an electrical ground. DO NOT place hands or fingers inside generator engine

compartment when engine is running.

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

PAGE 10 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ) — 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

cables are 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

of electrical shock, electrocution, and even

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

WET

HANDS

NEVER grab or

touch a live power cord with wet hands , the possibility exists

POWER

CORD

(POWER ON)

death!

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

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.

DANGERDANGER

DANGER

DANGERDANGER

■

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

electrocution, electrical shock or burn,

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 11

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

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

Keep the machinery in proper running condition. Fix damage to the machine immediately and always replace

broken parts.

DCA-125USJ (50 HZ)— 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 engine technical questions or information.

DANGER:DANGER:

DANGER:

DANGER:DANGER:

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.

John Deere Engine Owner's Manual

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains

negative battery terminal

manual mode

National Electrical Code

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

for

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.

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.

always

clothing or skin

Towing Safety Precautions

, rinse skin or clothing

wear safety glasses.

” for

PAGE 12 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— 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.”

■

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 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 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-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 13

DCA-125USJ (50 HZ)— INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— 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-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 15

DCA-125USJ (50 HZ)— TOWING SAFETY 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-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— 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.

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.

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 Width - 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 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.

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.

for lug nut tightening and

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-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 17

DCA-125USJ (50 HZ)— GENERATOR DECALS

The DCA-125USJ (50 HZ)generator is equipped with a number of safety decals (Figure 4). 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 4. Generator Decals

PAGE 18 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— GENERATOR DECALS

Figure 4. Generator Decals (Cont.)

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 19

DCA-125USJ (50 HZ)— GENERAL INFORMATION

DCA-125USJ (50 HZ) Series Familiarization Generator

The MQ Power Model DCA-125USJ (50 HZ)is a 80 kW

generator

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

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 100/200V output receptacles (CS-6369), 50A

Three auxilliary circuit breakers, 50A

Two 100V output receptacles (GFCI), 20A

Two GFCI circuit breakers, 20A

Five output terminal lugs (3Ø power)

Battery Charger (Optional)

Water Heater (Optional)

(Figure 5) that is designed as a high quality

Generator Control

, is provided with the following:

Open Delta Excitation System

The DCA-125USJ (50 HZ)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 (50 HZ)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 20 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— MAJOR COMPONENTS

Figure 5. Major Components

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DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 21

NOTE PAGE

PAGE 22 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-125USJ

6).

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 50 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.

(50 HZ)Generator Control Panel

(Figure

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 (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 23

DCA-125USJ (50 HZ)— ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 24 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

DCA-125USJ (50 HZ)— ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-125USJ

7).

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 50

Hz operation. This meter should indicate 1500 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.

(50 HZ)Engine Operating Panel

(Figure

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 239°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.

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

fault.

DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05) — PAGE 25

DCA-125USJ (50 HZ)— 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) 100/200V output receptacles @ 50 amp

Three (3) Circuit Breakers @ 50 amps

Two (2) 100V 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 26 — DCA-125USJ (50 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (03/11/05)

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