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MQ Power WHISPERWATT DCA125SSIU, Operation And Parts Manual

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PAGE 50 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) 

TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, 
use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller 
unit (MPEC). If the problem cannot be remedied, consult our company's business offi ce or service plant. 

Engine Controller Troubleshooting (MPEC)

Table 18. 

Symptom

Possible Problem

Solution

Low oil pressure light is on.

Low oil level?

Fill oil level.

Oil pressure sending unit failure?

Replace oil pressure sending unit.

Time delay malfunction in controller?

Refer to dealer.

Wire shorted?

Inspect/repair wire.

High coolant temperature 
light is on.

Fan belt tension incorrect?

Tighten/replace fan belt.

Air fl ow is not circulating through radiator?

Clean/repair radiator grill.

Doors open?

Close doors.

Exhaust leaking?

Replace/repair gaskets or faulty part.

Generator being overloaded?

Check/reduce load.

Thermostat failure?

Replace thermostat.

Air intake blocked?

Clean all air intakes.

Temperature switch failure

Replace temperature switch.

Overcrank light is on.

No or low fuel?

Fill fuel level.

Controller needs to be calibrated?

Refer to dealer.

Overspeed light is on.

RPM engine speed too high?

Adjust RPM.

Governor actuator needs to be adjusted?

Adjust governor actuator.

Governor controller needs to be adjusted?

Adjust governor controller.

Engine controller needs to be calibrated?

Refer to dealer.

Overspeed and engine start 
lights are on at same time..

Magnetic pickup out of adjustment?

Adjust magnetic pickup.

Magnetic pickup dirty?

Clean magnetic pickup.

Is magnetic pickup cable connected?

Inspect magnetic pickup cable and 
connect cable securely.

Summary of Contents for WHISPERWATT DCA125SSIU

Page 1: ... ALL TIMES To find the latest revision of this publication visit our website at www mqpower com WHISPERWATT SERIES MODEL DCA125SSIU 50HZ GENERATOR ISUZU 4HK1X DIESEL ENGINE PARTS LIST NO M3870301204 Revision 0 12 22 08 OPERATION AND PARTS MANUAL ...

Page 2: ...PAGE 2 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 PROPOSITION 65 WARNING Diesel engine exhaust and some of ...

Page 3: ...may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NH...

Page 4: ...tor Start Up Procedure Manual 34 35 Generator Start Up ProceduRe Auto Mode 36 Generator Shut Down Procedures 37 Maintenance 38 41 Trailer Maintenance 42 44 Trailer Wiring Diagram 45 Generator Wiring Diagram 46 Engine Wiring Diagram 47 Controller Wiring Diagram 48 Troubleshooting Generator 49 Troubleshooting Engine Controller 50 Troubleshooting Diagnostic Lamp 51 Explanation Of Code In Remarks Colu...

Page 5: ...ger for more information Order via Internet Dealers Only Orderpartson lineusingMultiquip sSmartEquipwebsite View Parts Diagrams Order Parts PrintSpecificationInformation Note Discounts Are Subject To Change Gotowww multiquip comandclickon Order Parts to log in and save Use the internet and qualify for a 5 Discount on Standard orders for all orders which include completepartnumbers Order via Fax De...

Page 6: ... 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 Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY CAUTION Indicates a hazardous situatio...

Page 7: ...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 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 equipmen...

Page 8: ... 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 operatin...

Page 9: ...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 ...

Page 10: ...pplicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death 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 in...

Page 11: ...he battery in a well ventilated environmenttoavoidtheriskofadangerousconcentration 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 hospi...

Page 12: ...r 200V Frequency 50 Hz Speed 1500 rpm Aux AC Power Single Phase 50 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 Engine Specifications Table 2 Model ISUZU 4HK1X Type 4 cycle water cooled direct injection turbo charged with charged air cooled No of Cylinders 4 cylinders Bore x Stroke 4 53 in x 4 92 in 115 mm x 125 mm Displacement 317 cu in 5 193 cc Starting Electric Coolant Capacity 5 30 gal 20 2 liters ...

Page 13: ...PAGE 13 DIMENSIONS Dimensions Figure 1 Dimensions Table 3 Reference Letter Dimension in mm Reference Letter Dimension in mm A 34 76 in 883 mm F 120 in 3 050 mm B 34 76 in 883 mm G 55 11 in 1 400 mm C 37 20 in 945 mm H 43 30 in 1 100 mm D 38 18 in 970 mm E 37 20 in 945 mm ...

Page 14: ...PAGE 14 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 INSTALLATION Typical Generator Grounding Application Figure 2 ...

Page 15: ...bration 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 CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves The...

Page 16: ...rom 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...

Page 17: ...TEM NO DESCRIPTION 1 Muffler Assembly 2 Air Filter Assembly 3 Voltage Selector Switch 4 Output Terminal Panel Assembly 5 Generator Assembly 6 Output Receptacles Assembly 7 Engine Assembly 8 Battery Assembly 9 Fuel Tank Assembly 10 Main Circuit Breaker Assembly 11 Generator Engine Operating Panel Assembly Major Components Figure 3 ...

Page 18: ...C voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off Frequency Meter 5 Indicates the output frequency in hertz Hz Normally 50 Hz AC Ammeter 6 Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch AC Voltmeter 7 Indicates the output voltage present at the U V and W O...

Page 19: ...DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 PAGE 19 NOTES ...

Page 20: ...AL REV 0 12 22 08 ENGINE OPERATING PANEL Engine Operating Panel Figure 5 A V HZ OFF W U V OFF W U V W U V DECREASE INCREASE AUTO MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO 20001Q 1 2 3 4 5 8 9 10 7 6 11 ...

Page 21: ...CU will attempt to crank the 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 Over Speed Protection mode Also the engine controller will shut down the en...

Page 22: ...tor Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel Figure 6 is provided with the 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 Eight 8 Output Term...

Page 23: ...function Both receptacles should be tested at least once a month G F C I Receptacle Figure 7 Twist Lock DualVoltage 100 200VAC Receptacles There are three 100 200V 50 amp auxiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 100 200V Twist Lock Au...

Page 24: ...put terminals from overload a 3 pole 300A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Connecting Loads Figure 10 Over Current Relay An over current relay Figure 11 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can ...

Page 25: ...Load Table 5 Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation An inadequate size connecting cable which cannot carry the required lo...

Page 26: ... 12 Voltage Selector Switch Locking Button The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running To lock the voltage selector switch press and hold the red button located at the bottom of the switch CAUTION NEVER change the position of the voltage selector switch while the engine is running ALWAYS place circuit breaker in...

Page 27: ...e 14 to activate the AC Voltmeter Gauge Figure 15 and read the available voltage between the two lugs For example to measure the voltage between theW and U terminal lugs set the ACVoltmeter Change Over Switch to W U and read the AC Voltmeter Gauge NOTICE For 3Ø 200V 1Ø 115V place the Voltage Selector Switch in the 3 Phase 340 139 position AC Voltmeter Figure 14 Change Over Switch AC Voltmeter Figu...

Page 28: ... Figure 18 3Ø 240 139V Position Connect the load wires to the UVWO terminals as 2 shown in Figure 19 UVWO Terminal Lugs Figure 19 3Ø 220 127V Connections Turn the voltage regulator knob Figure 20 clockwise 3 to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required Voltage Regulator Knob ...

Page 29: ...ge regulator adjustment knob whenever fine tuning of the output voltage is required 1Ø 200 100V UVWOTerminal Output Voltages Place the voltage selector switch in the 1Ø 240 120 1 position as shown in Figure 25 Voltage Selector Switch Figure 25 1Ø 240 120V Position Connect the load wires to the UVWO terminals as 2 shown in Figure 26 UVWO Terminal Lugs Figure 26 1Ø 200 100V Connections Turn the volt...

Page 30: ...with the specified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD API Service Classification CC SE API Service Classification CC SF Recommended Motor Oil Table 9 FUEL CHECK Refilling the Fuel System T...

Page 31: ...WAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fuel when refueling Open cabinet doors on the right side of the generator 2 from generator control panel position Remove fuel cap and fill tank Figure 30 Fueling the Generator Figure 30 NEVER overfill fuel tank 3 It is important to r...

Page 32: ... cause severe burns Coolant Capacity Table 10 Engine and Radiator 5 3 gal 20 2 liters Reserve Tank 2 quarts 1 9 liters Anti Freeze Table 11 OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 CLEANINGTHE RADIATOR The engine may overheat if the radiator fins become overloaded with dust or d...

Page 33: ...nal FIRST and reconnect negative terminal LAST When connecting battery do the following NEVER 1 connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position ALWAYS make sure that the MPEC Control Switch is in the OFF RESET position when connecting the battery Place a small amount of battery terminal treatment 2 compound around both battery termi...

Page 34: ...nuallystarttheenginewiththemain GFCIor auxiliary circuit breakers in the ON closed position INCORRECT CORRECT STARTING MANUAL Place the engine speed switch Figure 37 in the LOW 1 down position Engine Speed Switch Low Figure 37 Place the 2 MPEC control switch in the MANUAL position to start the engine Figure 38 MPEC Control Switch Figure 38 Manual Position Depending on the temperature of the coolan...

Page 35: ...e oil pressure of the engine Under normal operating conditions the oil pressure is approximately 42 to 71 psi 290 490 kPa Oil Pressure Gauge Figure 46 The 10 coolant temperature gauge Figure 47 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 167 203 F 75 95 C Green Zone Coolant Temperature Gauge Figure 47 The 11 tachometer gauge Fig...

Page 36: ...hen running the generator in the AUTO mode rememberthegeneratorcanstartupatanytimewithout warning NEVER attempt to perform any maintenance when the generator is in the auto mode CAUTION The engine speed switch must be set to the High position when running in the auto start mode Failing to set the switch in the proper position can result in damage to your generator when it turns on NOTICE When the ...

Page 37: ...nutes with no load applied Place the 4 MPEC Control Switch Figure 54 to the OFF RESET position MPEC Control Switch Off Reset Figure 54 Verify that 5 all the status LEDs on the MPEC display are OFF not lit Remove all loads from the generator 6 Inspect entire generator for any damage or loosening 7 of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in...

Page 38: ... Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X MAINTENANCE GENERAL INSPECTION Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oil and coolant leaks Use Table 12 as a general maint...

Page 39: ...posits or debris that have accumulated inside the fuel tank Fuel Tank Cleaning Figure 56 FUELTANK INSPECTION In addition to cleaning the fuel tank the following components should be inspected for wear Rubber Suspension look for signs of wear or deformity due to contact with oil Replace the rubber suspension if necessary Fuel Hoses inspect nylon and rubber hoses for signs of wear deterioration and ...

Page 40: ...nufacturer Close radiator cap tightly Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed DO NOT clean radiator core with any objects such as a screwdriver WARNING Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or steam RADIATOR CLEANING The radiator Figure 57 should be sprayed...

Page 41: ...ort device with maximum pound requirement from the tongue of the trailer Coupler 7 Type of hitch used on the trailer for towing Tire Size 8 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 Tire Ply 9 The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub 10 The wh...

Page 42: ... surge brakes Figure 58 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks or blockage Hydraulic Brake Components Figure 58 Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer tow...

Page 43: ...ith great force and cause serious eye or bodily injury Tire WearTroubleshooting Table 14 Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacturer Edge Wear Under inflation Adjust pressure to particular load per tire manufacturer Side Wear Loss of camber or overloading Make sure load does not exceed axle rating Align wheels Toe Wear Incorrect t...

Page 44: ...and 1 Torque all lug nuts in sequence see Figure 60 2 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 16 After first road use retorque all lug nuts in sequence 3 Check all wheel lug nuts periodically TireTorque Requirements Table 16 Wheel Size First Pass FT LBS Second Pass FT LBS Third Pass FT LBS 12 20 25 35 40 50 65 13 20 25 35 40 5...

Page 45: ...DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 PAGE 45 TRAILER WIRING DIAGRAM Trailer Towing Vehicle Wiring Diagram Figure 61 ...

Page 46: ...SS AC GENERATOR B L G V P R W Y O BR GR LB LG COLOR CODE WIRE COLOR BLACK BLUE BROWN GREEN GRAY VIOLET PINK ORANGE LIGHT GREEN LIGHT BLUE YELLOW WHITE RED WIRE COLOR W X Y W X Y T VS R S R W L Y Y V1 V1 RY2 W V O S R T AS Y G A J K B A D C P1P2 k 3 1 3 1 2 A B C D CN4 CN2 GR Y GR A V R VR CN1 RY1 V2 V2 OCa 98 97 W 41 43 13 15 9 33 29 37 SW CB1 W V U T C R G W G G HOT W G HOT U2 V2 W2 V1 W1 U1 U3 V...

Page 47: ...DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 PAGE 47 ENGINE WIRING DIAGRAM Engine Wiring Diagram Figure 63 ...

Page 48: ...PAGE 48 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 CONTROLLER WIRING DIAGRAM Controller Wiring Diagram Figure 64 ...

Page 49: ...eter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 17 3 ohms across J K on CN1 Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Outpu...

Page 50: ...tension incorrect Tighten replace fan belt Air flow is not circulating through radiator Clean repair radiator grill Doors open Close doors Exhaust leaking Replace repair gaskets or faulty part Generator being overloaded Check reduce load Thermostat failure Replace thermostat Air intake blocked Clean all air intakes Temperature switch failure Replace temperature switch Overcrank light is on No or l...

Page 51: ...mly lit when the MPEC Control Switch is placed in the MANUAL position If engine trouble occurs the diagnostic lamp will be 2 brightly lit as long as the control switch is left in the manual position The diagnostic lamp will indicate that an engine 3 malfunction has occurred NOTICE For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruction ma...

Page 52: ...part number at time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R AsRequired isgenerallyusedforhosesorotherparts that are sold in bulk and cut to length A blank entry generally indicates...

Page 53: ...TER OIL 5 0602042590 FILTER FUEL MAIN 5 8980088400 ELEMENT FUEL MAIN 5 8980758550 ELEMENT FUEL PRE 5 8980714010 FILTER FUEL FEED PUMP 2 0605505070 CAP FUEL 5 0602046684 ELEMENT AIR CLEANER 5 0602046685 ELEMENT AIR CLEANER 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNIT WATER TEMPERATURE 1 0601810245 BULB ALARM LAMP 1 8980527130 FAN BELT 1 0602202641 CONTROLLER ECU 1 0601870440 CIRCUIT BREAKER 1P ...

Page 54: ...PAGE 54 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 GENERATOR ASSY ...

Page 55: ...0000503 STARTER ASSY 1 3 0845041804 GROMMET 2 4 8131315202 END BRACKET 1 5 8101350013 EXCITER FIELD ASSY 1 6 0012110060 HEX HEAD BOLT 4 7 0042610000 WASHER LOCK 4 8 0041210000 WASHER FLAT 4 9 0010112035 HEX HEAD BOLT 6 10 0040012000 WASHER LOCK 6 11 0041212000 WASHER FLAT 6 12 8131310104 BEARING COVER 1 13 8131312204 BEARING GASKET 1 14 8131331003 END BRACKET COVER 1 15 0017106012 HEX HEAD BOLT 10...

Page 56: ...PAGE 56 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 CONTROL BOX ASSY ...

Page 57: ... 13 0601802218 FUSE HOLDER 1 13A 0601806671 FUSE 15A 3 14 0027103016 MACHINE SCREW 2 15 0601815153 TERMINAL 1 16 0027104016 MACHINE SCREW 2 17 8121468300 INLET AIR TEMP SENSOR 1 REPLACES P N 0603210240 18 M3260500503 ELECTRIC PARTS SET PANEL 1 19 0016906016 HEX HEAD BOLT 4 20 8980710280 CONTROLLER 1 REPLACES P N 0602202686 21 M3206500604 BRACKET 1 22 0066906016 HEX HEAD BOLT 4 23 0601831205 PUSH B...

Page 58: ...PAGE 58 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 CONTROL BOX ASSY ...

Page 59: ...TRIP 1 47 M3213602304 SWITCH COVER 1 48 0016906016 HEX HEAD BOLT 10 49 0016906016 HEX HEAD BOLT 19 49A 0040506000 TOOTHED WASHER 1 50 M3223001103 CONTROL PANEL 1 51 0601807641 FREQUENCY METER 45 65Hz 240V 1 52 0601808988 AC AMMETER O 200A 400 1 53 0601801040 AMMETER CHANGE OVER SWITCH 1 54 0601806859 AC VOLTMETER O 600V 1 55 0601801041 VOLTMETER CHANGE OVER SWITCH 1 56 0601840073 RHEOSTAT VR 2W 1k...

Page 60: ...PAGE 60 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 CONTROL BOX ASSY ...

Page 61: ...0080200007 SNAP RING 2 76 0602122272 OIL PRESSURE UNIT 1 77 M9200100004 ADAPTER 1 78 8943998582 ADAPTER 1 REPLACES P N 0602020220 79 0602123260 WATER TEMPERATURE UNIT 1 80 9095720140 PACKING 1 REPLACES P N 0602021109 81 0602120465 TACHOMETER PICK UP 1 82 0601806644 FUSE 30A 1 83 0601806640 FUSE 65A 1 84 M3246702804 WIRE HARNESS GENERATOR 1 85 M3257201702 WIRE HARNESS ENGINE 1 86 M3357201802 WIRE H...

Page 62: ...PAGE 62 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 ENGINE AND RADIATOR ASSY ...

Page 63: ...HOSE BAND 4 15 M3923200124 INTER COOLER 1 16 0132004000 PLUG 1 17 M3310502403 COOLER HOSE 1 18 M3310502503 COOLER HOSE 1 19 0605515208 HOSE BAND 2 20 0605515204 HOSE BAND 1 21 0605515207 HOSE BAND 1 22 0602046258 AIR CLEANER 1 22A 0602046684 AIR CLEANER ELEMENT 1 22B 0602046685 AIR CLEANER ELEMENT 1 23 0602040650 AIR CLEANER INDICATOR 1 24 0602040596 AIR CLEANER BAND 2 25 0016908020 HEX HEAD BOLT ...

Page 64: ...PAGE 64 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 ENGINE AND RADIATOR ASSY CONTINUED ...

Page 65: ...41221 46 0010110120 HEX HEAD BOLT 2 46A 0040010000 WASHER LOCK 2 46B 0041210000 WASHER FLAT 2 47 0010110150 HEX HEAD BOLT 2 47A 0040010000 WASHER LOCK 2 47B 0041210000 WASHER FLAT 2 50 0602022535 ADAPTER 4 51 0602022930 HOSE JOINT 4 52 0192101250 HOSE 2 53 0605515198 HOSE BAND 4 54 M3316200004 RESERVE TANK BRACKET 1 55 0016908020 HEX HEAD BOLT 2 56 M9300000203 RESERVE TANK 1 57 0602010900 RESERVE ...

Page 66: ... 0 12 22 08 OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 67: ...G RING 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 OUTLET COVER CABLE 1 16 M3236300004 CABLE OUTLET COVER SUPPORTER 1 17 0016906020 HEXHEAD BOLT 6 18 0601815194 TERMINAL BLOCK 1 19 0027104016 MACHINE SCREW 2 20 0603306775 BLIND PLUG 2 21 0027104016 MACHINE SCREW 4 22 0601870440 CIRCUIT BREAKER 1P 20A 3 23 0601870441 CIRCUIT BREAKER 2P 50A 3 24 M1260700504 BREAKER COVER FITTING 1 24 1 0222100100...

Page 68: ...PAGE 68 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 BATTERY ASSY ...

Page 69: ... REMARKS 1 0602220198 BATTERY 1 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 M3346901404 BATTERY CABLE 1 5 M3346901504 BATTERY CABLE 1 7 CABLE 1 MAKE LOCALLY 8 0030010000 HEX NUT 1 8A 0040010000 WASHER LOCK 1 9 0017110030 HEX HEAD BOLT 2 9A 0040510000 TOOTHED WASHER 2 ...

Page 70: ...PAGE 70 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 MUFFLER ASSY ...

Page 71: ...3330100902 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M3333001403 EXHAUST PIPE 1 4 1141451840 GASKET 1 REPLACES P N 0602320108 5 M3333200004 GASKET 1 6 0039308000 HEX NUT 8 7 0017110040 HEX HEAD BOLT 4 8 M3330400304 COVER 1 9 M3330400403 BRACKET 1 10 M3333300304 BRACKET 1 11 0016908020 HEX HEAD BOLT 6 12 0602326061 U BOLT SET 2 ...

Page 72: ...PAGE 72 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 FUEL TANK ASSY ...

Page 73: ...OLT 4 15 8980139861 MAIN FUEL FILTER 1 REPLACES P N 0602042426 15A 8980088400 FUEL FILTER ELEMENT 1 REPLACES P N 0602042515 16 8980758550 PRE FUEL FILTER 1 REPLACES P N 0602042405 16A 8980758540 FUEL FILTER ELEMENT 1 REPLACES P N 0602042516 17 8973834270 JOINT PIPE 4 REPLACES P N 0602042661 18 1096750951 JOINT BOLT 4 REPLACES P N 0602042621 19 1096300860 PACKING 8 REPLACES P N 0602042641 20 001711...

Page 74: ...REV 0 12 22 08 ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 75: ...025 HEX HEAD BOLT 4 14 0016910025 HEX HEAD BOLT 2 15 M3310202403 INTER COOLER BRACKET 2 16 0016910025 HEX HEAD BOLT 8 17 0017110020 HEX HEAD BOLT 8 18 M3310303303 FAN SHROUD 1 19 M3310303403 FAN SHROUD 1 20 0016908020 HEX HEAD BOLT 8 21 0016908020 HEX HEAD BOLT 4 21A 0207008000 HEX NUT 4 22 M3310303603 FAN GUARD 1 23 M3310303503 FAN GUARD 1 24 M3310303703 FAN GUARD 1 25 0016908020 HEX HEAD BOLT 16...

Page 76: ... 12 22 08 ENCLOSURE ASSY CONTINUED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 77: ... HEX HEAD BOLT 37 46 M3310600004 COVER 1 47 0019208020 HEX HEAD BOLT 4 48 M3453201602 SPLASHER PANEL 1 48A M3493426404 ACOUSTIC SHEET 1 49 0019108055 HEX HEAD BOLT 4 49A 0042308000 WASHER LOCK 4 49B 0042408000 WASHER FLAT 4 50 0016910025 HEX HEAD BOLT 2 51 M3453004903 SIDE DOOR 1 51A M3493425703 ACOUSTIC SHEET 1 52 M3453005003 SIDE DOOR 1 52A M3493425903 ACOUSTIC SHET 1 53 M3453005103 SIDE DOOR 1 ...

Page 78: ... 12 22 08 ENCLOSURE ASSY CONTINUED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 79: ...E SCREW 4 64 M3453700004 GUTTER 1 65 0019206015 HEX HEAD BOLT 4 66 M9110100204 HINGE 4 66A M9116100004 WASHER 4 67 M9110100304 HINGE 4 67A M9116100004 WASHER 4 68 0019208020 HEX HEAD BOLT 9 69 0601850097 STOPPER 8 70 0027208025 MACHINE SCREW 8 71 M9310000004 BLIND PLUG 8 72 0016908020 HEX HEAD BOLT 1 72A 0040508000 TOOTHED WASHER 1 ENCLOSURE ASSY CONTINUED ...

Page 80: ...PAGE 80 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 RUBBER SEALS ASSY ...

Page 81: ...UBBER SEAL 3 4 0228901050 RUBBER SEAL 3 5 0228900904 RUBBER SEAL 4 6 0228900470 RUBBER SEAL 1 7 0228900530 RUBBER SEAL 1 8 0229201040 RUBBER SEAL 1 9 0228800970 RUBBER SEAL 2 10 0228800590 RUBBER SEAL 1 11 0228800630 RUBBER SEAL 1 12 0228100665 RUBBER SEAL 1 13 0228100370 RUBBER SEAL 1 14 0228100300 RUBBER SEAL 1 15 0228100365 RUBBER SEAL 1 16 0228100280 RUBBER SEAL 1 17 0228100070 RUBBER SEAL 1 ...

Page 82: ...PAGE 82 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 NAMEPLATE AND DECALS ASSY ...

Page 83: ...92020040 ENGINE RADIATOR GROUP 3 1 M9500000004 DECAL OIL DRAIN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9503000004 DECAL WARNING MOVING PARTS 2 M90300000 3 4 M9503000103 DECAL WATER OIL CHECK 1 M90300010 3 5 M9503100004 DECAL WARNING HOT COOLANT 1 M90310000 3 6 M9510100004 DECAL CAUTION HOT PARTS 1 M91010000 OUTPUT TERMINAL GROUP 4 1 M1550000204 DECAL NOTE 1 M15000020 4 2 M155...

Page 84: ...PAGE 84 DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 NAMEPLATE AND DECALS ASSY CONTINUED ...

Page 85: ...ENCLOSURE GROUP 8 1 M9510200002 DECAL MQ 1 M91020000 8 2 060050090 EMBLEM 1 8 2A 0021106016 MACHINE SCREW 2 8 3 M3560100003 STRIPE 1 8 4 M3560100103 STRIPE 2 8 5 M3560103804 STRIPE 1 8 6 M3560100303 STRIPE 1 8 7 M3560100404 STRIPE 2 8 8 M3560100503 STRIPE 1 8 9 M3560100604 STRIPE 2 8 10 M3560103504 STRIPE 1 8 11 M3560103604 STRIPE 1 8 12 M3560103704 STRIPE 1 8 13 M3550002204 DECAL CAUTION 1 M35000...

Page 86: ... andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 Thesenderwillbenotifiedofanymaterial receivedthatisnotacceptable 8 Suchmaterialwillbeheldforfiveworking days from notification pending instruc tions Ifareplyisnotreceivedwithinfive days thematerialwillbereturnedtothe senderathisexpense 9 Creditonreturnedpartswillbeissuedat dealer net price at time of the original purchase lessa15 res...

Page 87: ...DCA125SSIU 50 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 12 22 08 PAGE 87 NOTES ...

Page 88: ... this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligat...

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