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PAGE 60 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TROUBLESHOOTING (GENERATOR)

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Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the table shown below for diagnosis based on the Generator Troubleshooting (Table 20). If the problem
cannot be remedied, consult our company's business office or service plant.

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Содержание MQ POWER DCA-125SSJU

Страница 1: ...T 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 E mail mq multiquip com z z z z z www multiquip com COPYRIGHT 2003 MULTIQUIP INC PARTS LIST NO 3870300064A S N7500469 UPTO 7500507 125SSJU...

Страница 2: ...PAGE 2 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03...

Страница 3: ...EASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 421 1244 FAX 310 537 4259 TECHNICAL ASSI...

Страница 4: ...ntents 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...

Страница 5: ...00 Ext 279 Multiquip s Main Phone Numbers 800 421 1244 Fax 310 537 3927 310 537 3700 Note Unlessotherwiseindicatedbycustomer all orders are treated as Standard Orders and will ship within 24 hours We...

Страница 6: ...e w o P 8 0 l l u F A B d l e v e L d n u o S t e e f 3 2 t a d a o L 7 6 n o i t a l u s n I F s s a l C s n o i t a c i f i c e p S e n i g n E l e d o M 0 5 2 F T 8 6 0 6 E R E E D N H O J e p y T...

Страница 7: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 7 DCA 125SSJU SERIES DIMENSIONS Figure 1 Dimensions...

Страница 8: ...ses 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 ampl...

Страница 9: ...can result if operating in speed ranges above maximum allowable Respiratory Hazard ALWAYS wear approved respiratory protection ALWAYS wear approved eye and hearing protection Sight and Hearing hazard...

Страница 10: ...sion or fire could result causing severe bodily harm or even death High Temperatures Allow the engine to cool before performing service and maintenance functions Contact with hot components can cause...

Страница 11: ...stop the machine and place the circuit breaker in the OFF positionwhencontact with the output terminals is required There exists the possibility of electrocution electrical shock or burn which can ca...

Страница 12: ...ery is not charged a buildup of combustible gas will occur 4 ALWAYSkeepbatterychargingandcablesingoodworking condition Repair or replace all worn cables 5 ALWAYS recharge the battery in an vented air...

Страница 13: ...iler tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles ALWAYSmake sure the trailer is equipped with a Safety Chain ALWAYS attach trailer s safety chains to towing...

Страница 14: ...PAGE 14 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 Figure 2 Typical Generator Grounding Application DCA 125SSJU SERIES INSTALLATION...

Страница 15: ...rger 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 othe...

Страница 16: ...trailer Also check the tire tread wear on both vehicles ALWAYSmake sure the trailer is equipped with a Safety Chain DCA 125SSJU SERIES TOWING SAFTEY PRECAUTIONS ALWAYSattach trailer s safety chain to...

Страница 17: ...condition Check the tires for proper inflation and wear Also check the wheel lug nuts for proper tightness 5 Frame Length Measurement is from fender to fender 6 Jack Stand Trailer support device with...

Страница 18: ...B L 0 0 8 L E E H W T L I T L L U F W 0 7 R L R T 0 6 5 4 A C D 0 7 O N E G R U S S B L 0 0 0 7 6 8 1 7 7 B L 0 0 0 2 D A P T A L F X 0 7 R L R T 0 6 5 4 A C D 0 7 T P O E G R U S S B L 0 0 0 7 8 3 1...

Страница 19: ...X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 E L O P 4 T A L F R E B B U R X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 E L O P 4...

Страница 20: ...th a number of safety decals These decals are provided for operator safety and maintenance information The illustration below and on the preceding page show the decals as they appear on the machine Sh...

Страница 21: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 21 DCA 125SSJU SERIES GENERATOR DECALS...

Страница 22: ...of the open delta A B C and D Duringsteadystateloads thepowerfromthevoltageregulator 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 t...

Страница 23: ...N O I T P I R C S E D 1 y l b m e s s A r e l f f u M 2 y l b m e s s A e n i g n E 3 y l b m e s s A e r u s o l c n E 4 y l b m e s s A r o t a r e n e G 5 y l b m e s s A l a n i m r e T t u p t u...

Страница 24: ...itched off 5 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 6 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz 7 AC Voltmeter Ind...

Страница 25: ...g supplied by the engine s alternator which provides current for generator s control circuits and battery charging system Figure 6 Engine Operating Panel Up To S N 7500507 6 Fuel Gauge Indicates amoun...

Страница 26: ...PAGE 26 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES ENGINE OPERATING PANEL Figure 7 Engine Operating Panel From S N 7500508...

Страница 27: ...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...

Страница 28: ...cles 20 amp z Two 2 GFCI Circuit Breakers 120V 20 amps z One 300 Amp Main Circuit Breaker z Five 5 Output Terminal Lugs Output Terminal Panel The Output Terminal Panel Figure 8 shown below is located...

Страница 29: ...minals Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning the knob counter clockwise will...

Страница 30: ...circuit breakers to the OFF position prior to starting the engine DCA 125SSJU SERIES OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current Relay An over current relay Figure 14 is connected to the main...

Страница 31: ...up to the generating set s rated output kW can be used z When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output kW multiplied by 0 6 can be used z When co...

Страница 32: ...r 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 Figure 15 Voltage Selector Switch DCA 1...

Страница 33: ...output on the selected leg Figure 16 Voltage Selector Switch 240 139V Three Phase Position for 3 208V 120V voltage Figure 17 AC Voltmeter Change Over Switch Figure 18 AC Voltmeter Gauge Volt reading o...

Страница 34: ...minal Lugs 240 139V Three Phase Connections 2 Connect the load wires to the UVWO terminals as shown in Figure 22 3 Turn the voltage regulator knob Figure 23 clockwise to increase voltage output turn c...

Страница 35: ...increase voltage output turn counterclockwise to decrease voltage output 1 240V 120V UVWOTerminal OutputVoltages 1 Place the voltage selector switch in the 1 240 120 position as shown in Figure 30 Fig...

Страница 36: ...y be substituted if they meet the following requirements WARNING WARNING WARNING WARNING WARNING ONLY properly trained personel who have read and understand this section should refill the double fuel...

Страница 37: ...ll trailer fuel tank Figure 37 first Figure 37 Fuel Tank Filling Order CAUTION CAUTION CAUTION CAUTION CAUTION DANGER DANGER DANGER DANGER DANGER WARNING WARNING WARNING WARNING WARNING Figure 36 Only...

Страница 38: ...or fuel expansion Fuel expands when heated 4 Once the trailer tank is full the secondary inner tank can be filled See Figure 39 Notice how the trailer filler tube level rises when the internal tank is...

Страница 39: ...dded Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is da...

Страница 40: ...ng or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose cla...

Страница 41: ...terminals are protected by a plastic cover remove this cover to gain access to the terminals Tighten terminal nuts securely to prevent load wires from slipping out 1 Placethemain G F C I andaux circu...

Страница 42: ...ition Switch Start 9 Turn the ignition key to the START position Figure 52 and listen for the engine to begin cranking After the engine starts release the ignition key Figure 51 Engine Throttle Contro...

Страница 43: ...e coolant temperature Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit Green Zone Figure 59 Coolant Temperature Gauge Figure 61 Main Aux and G...

Страница 44: ...osition CAUTION Before Starting EngineOperatingPanelS N7500508 Steps 20 thru 31 are referenced for Engine Operating Panel S N 7500508 Figure 63 This unit does not have a key ignition switch or a throt...

Страница 45: ...er the generator can start up at any time without warning NEVER attempt to perform any maintenance when the generator is in the auto mode WARNING When connecting the generator to a isolation transfer...

Страница 46: ...Figure 45 to the OFF position 2 Place the engine throttle control in the LOW position Figure 71 Figure 71 Engine Throttle Control Low 3 Let the engine cool by running it for 3 5 minutes with no loada...

Страница 47: ...Air Cleaner with Dust Indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal shows RED mea...

Страница 48: ...out of fuel or after disassembling the fuel system bleed the system according to the following procedure To restart after running out of fuel turn the switch to the ON position for 15 30 seconds Try a...

Страница 49: ...ill ONLY function when commercial power has been supplied to them Figure 75 To apply commercial power to these receptacles a power cord of adequate size will be required SeeTable 5 When using the gene...

Страница 50: ...draulicsurgebrakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with...

Страница 51: ...he leaf suspension springs and associated components Figure 77 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace al...

Страница 52: ...ug nuts all the way down Tighten each lug nut in 3 separate passes as defined byTable 18 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically NEVER use an pne...

Страница 53: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 53 DCA 125SSJU SERIES TRAILERWIRING DIAGRAM Figure 79 Trailer Towing Vehicle Wiring Diagram...

Страница 54: ...PAGE 54 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES GENERATORWIRING DIAGRAM Figure 80 Generator Wiring Diagram...

Страница 55: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 55 DCA 125SSJU SERIES ENGINEWIRING DIAGRAM IGNITION SWITCH Figure 81 Engine Wiring Diagram Ignition Switch...

Страница 56: ...PAGE 56 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJUSERIES ENGINEWIRINGDIAGRAM ENGINECONTROLLER Figure 82 Engine Wiring Diagram Engine Controller...

Страница 57: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 57 NOTE PAGE...

Страница 58: ...w t f a h s m a c l e u F e c a l p e R d e g g o l c e l z z o n n o i t c e j n I e l z z o n n o i t c e j n i n a e l C g n i n o i t c n u f l a m p m u p n o i t c e j n I e c a l p e r r o r i...

Страница 59: ...v e l d e i f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i...

Страница 60: ...r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r a s s e c e n f i e c a l p e R t u p t u O e g a t l o V h g i H e s o o l s n o i t c e n n o c g n i r i w s I r i a p...

Страница 61: ...o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r o t a i d a r r i a p e r n a e l C n e p o...

Страница 62: ...e where a particular part is used Model Number Where indicated this shows that the correspondingpartisutilizedonlywiththisspecificmodelnumber or model number variant Items Found In the Items Number Co...

Страница 63: ...07 1 M3310500103 RADIATOR HOSE LOWER S N 7500001TO7500307 1 M3310500503 RADIATOR HOSE LOWER S N 7500307 5 0602041290 OIL FILTER 5 0602042590 FUEL FILTER 5 0602046377 AIR ELEMENT 3 0602042420 FUEL FILT...

Страница 64: ...PAGE 64 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES NAMEPLATE AND DECALS NAMEPLATE AND DECALS...

Страница 65: ...M90310000 16 M9503200004 DECAL WARNING 1 M90320000 17 M9510100004 DECAL CAUTION 1 M91010000 18 M9510200002 DECAL MQ 1 M91020000 19 M9520000004 DECAL GROUND 1 M92000000 20 M9520000104 DECAL AMMETER CHA...

Страница 66: ...PAGE 66 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES GENERATOR ASSY GENERATOR ASSY...

Страница 67: ...01020004 INSULATORWASHER 1 1 11 8001020504 INSULATORWASHER 1 1 12 0010110020 HEX HEAD BOLT 4 1 13 0040010000 LOCKWASHER 4 1 14 0601000209 BALANCING WEIGHT KIT 1 1 15 0071906312 BEARING 1 6312 DDU C3 2...

Страница 68: ...PAGE 68 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES GENERATOR ASSY CONT GENERATOR ASSY CONT...

Страница 69: ...EX HEAD BOLT 8 S N 7500001TO 7500242 21 0343204150 HEX HEAD BOLT 8 S N 7500243 22 EM923344 LOCKWASHER 8 REPLACES 0043604000 23 0070506306 BEARING 1 6306ZZ 24 0012810030 HEX HEAD BOLT 12 25 0012810030...

Страница 70: ...PAGE 70 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 CONTROL BOX ASSY DCA 125SSJU SERIES CONTROL BOX ASSY...

Страница 71: ...LA7D1064 12 M1260600004 FITTING BRACKET 1 S N 7500001TO 7500222 13 0021304015 MACHINE SCREW 2 REPLACES 0027104015 13 0030004000 HEX NUT 2 REPLACES 0207004000 14 0027105020 MACHINE SCREW 4 15 M3213500...

Страница 72: ...PAGE 72 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES CONTROL BOX ASSY CONT CONTROL BOX ASSY CONT...

Страница 73: ...1823240 RECTIFER 1 DE4503 41 0027104020 MACHINE SCREW 1 S N 7500001TO 7500307 41 0027105020 MACHINE SCREW 1 S N 7500308TO 7500507 41 0027104020 MACHINE SCREW 1 S N 7500508 42 0602200478 EMERGENCY RELA...

Страница 74: ...PAGE 74 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Страница 75: ...001 TO 7500307 16 M3310200204 RADIATOR BRACKET 1 S N 7500001 TO 7500307 17 M3310200404 RADIATOR BRACKET 1 S N 7500001 TO 7500307 18 0013006008 S N 7500001 TO 7500307 8 S N 7500001 TO 7500307 19 004300...

Страница 76: ...PAGE 76 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES ENGINE AND RADIATOR ASSY CONT ENGINE AND RADIATOR ASSY CONT...

Страница 77: ...592 RELAY AT141011 1 S N 7500263 57 0017106015 HEX HEAD BOLT 1 S N 7500001 TO 7500262 57 011808015 MACHINE SCREW 2 REPL 0027106015 S N 7500263 58 M3313100004 RADIATOR COVER 1 S N 7500001 TO 7500307 58...

Страница 78: ...PAGE 78 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY S N7500001 TO S N 7500507 S N 7500508...

Страница 79: ...AR58126 1 S N 7500001TO 7500507 16 0602100028 SET NUT R44342 1 S N 7500001TO 7500507 16 0602100029 SET WASHER A4827R 1 S N 7500001TO 7500507 17 0601831594 COLD STARTER BUTTON R39554 1 S N 7500001TO 75...

Страница 80: ...PAGE 80 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY...

Страница 81: ...UPPORTER CABLE OUTLET COVER 1 S N 7500001TO 7500034 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1 S N 7500035 17 011206020 HEX HEAD BOLT 6 REPLACES 0016906020 18 0601808803 CIRCUIT BREAKER 2 Q0U 120B...

Страница 82: ...PAGE 82 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES BATTERY ASSY BATTERY ASSY...

Страница 83: ...ARKS 1 0602220196 BATTERY 1 4D 2 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 0040006000 LOCKWASHER 2 6 M3346900004 BATTERY CABLE 1 7 M3346900104 BATTER...

Страница 84: ...PAGE 84 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES MUFFLER ASSY MUFFLER ASSY...

Страница 85: ...MARKS 1 M3330100002 MUFFLER 1 S N 7500001TO 7500072 1 0602300167 MUFFLER 1 S N 7500073 2 012210025 HEX HEAD BOLT 4 REPLACES 0016910025 3 M3333000303 EXHAUST PIPE 1 4 0602325066 CLAMP 1 5 M3333200004 G...

Страница 86: ...PAGE 86 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES FUELTANK ASSY FUEL TANK ASSY...

Страница 87: ...034 5 0207308000 HEX NUT 2 S N 7500035 5 0041208000 PLAIN WASHER 2 S N 7500001TO 7500034 6 0222100660 RUBBER SHEET 2 7 M9200000003 DRAIN JOINT 1 8 M9200200004 DRAIN BOLT 1 9 0150000018 O RING 1 AP18 1...

Страница 88: ...DCA 125SSJU SERIES ENCLOSURE ASSY ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GR...

Страница 89: ...000 HEX NUT 12 9 0040014000 LOCKWASHER 24 9 031114260 PLAINWASHER 24 REPLACES 0041214000 10 M3443000202 REAR FRAME 1 S N 7500001TO S N 7500507 10 M3443000212 REAR FRAME 1 S N7500508 10 M3493300204 ACO...

Страница 90: ...125SSJU SERIES ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBE...

Страница 91: ...PLACES 0016910025 34 M3453000703 SIDE DOOR 1 34 M3493400704 ACOUSTIC KIT A S FRONT DOOR L 1 35 M3453000603 SIDE DOOR 1 35 M3453400804 ACOUSTIC SHEET 1 36 M3453000503 SIDE DOOR L 1 36 M3493401004 ACOUS...

Страница 92: ...PAGE 92 DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 DCA 125SSJU SERIES RUBBER SEAL ASSY RUBBER SEAL ASSY...

Страница 93: ...1 3 0228901020 RUBBER SEAL 2 4 0228900990 RUBBER SEAL 4 5 0228900955 RUBBER SEAL 4 6 0228900470 RUBBER SEAL 2 7 0228900470 RUBBER SEAL 4 8 0229201040 RUBBER SEAL 1 9 0228800970 RUBBER SEAL 2 10 02288...

Страница 94: ...calcomponents f Paint chemicals andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for...

Страница 95: ...DCA 125SSJU SERIES STANDARD PARTS AND OPERATION MANUAL REV 4 06 03 03 PAGE 95 NOTE PAGE...

Страница 96: ...l mq multiquip com z z z z z www multiquip com OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 37...

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