Multiquip Portable Generator DCA 125SSJU User Manual

OPERATION AND PARTS MANUAL  
MQ POWER  
DCA-125SSJU  
DCA-125SSJU2  
PORTABLE  
GENERATOR  
(STANDARD)  
PARTS LIST NO. 3870300064A  
S/N7500469 UPTO 7500507-125SSJU  
S/N FROM 7500508-125SSJU2  
Revision #4 (06/03/03)  
MULTIQUIPINC.  
18910 WILMINGTON AVE.  
PARTS DEPARTMENT:  
800-427-1244  
CARSON, CALIFORNIA 90746 FAX: 800-672-7877  
310-537-3700  
800-421-1244  
FAX:310-537-3927  
SERVICE DEPARTMENT:  
800-835-2551  
FAX:310-638-8046  
E-mail:[email protected] z www:multiquip.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PAGE 2 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
HERE'S HOW TO GET HELP  
PLEASE 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 ASSISTANCE  
800-478-1244  
FAX: 310- 631-5032  
WARRANTY DEPARTMENT  
888-661-4279, or 310-661-4279  
FAX: 310- 537-1173  
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
DCA-125SSJU &  
DCA-125SSJU2  
AC GENERATOR  
COMPONENT DRAWINGS  
Name Plate And Decals ............................................ 64-65  
Generator Assembly.................................................. 66-69  
Control Box Assembly............................................... 70-73  
Engine & Radiator Assembly..................................... 74-77  
Engine Operating Panel Assembly ............................ 78-79  
Output Terminal Assembly......................................... 80-81  
Battery Assembly ...................................................... 82-83  
Muffler Assembly ...................................................... 84-85  
Fuel Tank Assembly .................................................. 86-87  
Enclosure Assembly ................................................. 88-91  
Rubber Seal Assembly .............................................. 92-93  
Here's How To Get Help .................................................... 3  
Table Of Contents ............................................................. 4  
Parts Ordering Procedures ...............................................5  
Specifications ...................................................................6  
Dimensions (Top, Side, Front) ...........................................7  
Safety Message Alert Symbols .................................... 8-9  
Rules for Safe Operation ........................................... 10-13  
Installation ................................................................. 14-15  
Towing Safety Precaution ............................................... 16  
Trailer Specifications ................................................. 17-19  
Generator Decals....................................................... 20-21  
General Information ........................................................ 22  
Major Components ......................................................... 23  
Generator Control Panel ................................................. 24  
Engine Operating Panel (up to S/N 7500507) ................. 25  
Engine Operating Panel (S/N 7500508~) ................... 26-27  
OutputTerminal Panel Familiarization ........................ 28-30  
Load Application ............................................................. 31  
Generator Outputs ..................................................... 32-33  
Gauge Reading ............................................................... 33  
OutputTerminal Panel Connections ........................... 34-35  
Pre Setup .................................................................. 36-40  
Generator Start-up Procedure (Manual) ..................... 41-44  
Generator Start-up Procedure (Auto Mode) .................... 45  
Generator Shut-Down Procedure .................................... 46  
Maintenance .............................................................. 47-49  
Trailer Brakes Maintenance ............................................ 50  
Trailer Maintenance.................................................... 51-52  
TrailerWiring Diagram ..................................................... 53  
GeneratorWiring Diagram ............................................... 54  
Engine Wiring Diagram (Ignition Switch) ......................... 55  
EngineWiring Diagram (w/ Controller) ............................ 56  
EngineTroubleshooting .............................................. 58-59  
GeneratorTroubleshooting .............................................. 60  
Engine ControllerTroubleshooting ................................... 61  
Explanation of Code in Remarks Column ....................... 62  
Suggested Spare Parts .................................................. 63  
Terms and Condition of Sale — Parts ............................ 94  
Specification and part  
number are subject to  
NOTE  
change without notice.  
PAGE 4 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PARTS ORDERING PROCEDURES  
When ordering parts,  
please supply the following information:  
Dealeraccountnumber  
Dealernameandaddress  
Shipping address (if different than billing address)  
Returnfaxnumber  
Applicable model number  
Quantity,part number and description of each part  
Specifypreferredmethodofshipment:  
Note:Unlessotherwiseindicatedbycustomer, 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.  
FedEx or UPS Ground  
FedEx or UPS Second Day or Third Day  
FedEx or UPS Next Day  
Federal Express Priority One  
DHL  
Truck  
Place Your Parts Order Via Web or Fax  
For Even More Savings!  
Here’s how to get help...  
Please have the model and serial number on  
hand when calling.  
Parts Department  
Extra Discounts!  
800-427-1244  
310-537-3700  
Fax:800-672-7877  
Fax:310-637-3284  
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:  
Mayco Parts  
800-306-2926  
310-537-3700  
Fax:800-672-7877  
Fax:310-637-3284  
Ordered  
via  
Standard  
orders  
Stock orders  
($750 list and above)  
Service Department  
800-478-1244  
310-537-3700  
Fax  
3%  
5%  
10%  
10%  
Fax:310-537-4259  
Web  
MQ Power Service Department  
Special freight allowances  
when you order 10 or more  
line items via Web or Fax!**  
FedEx Ground Service at no charge for freight  
800-835-2551  
310-537-3700  
Fax:310-638-8046  
Warranty Department  
800-421-1244, Ext. 279  
310-537-3700, Ext. 279  
Fax:310-537-1173  
No other allowances on freight shipped by any other  
carrier.  
Multiquip’s Main Phone Numbers  
800-421-1244  
310-537-3700  
Fax:310-537-3927  
NOTE:DISCOUNTSARESUBJECTTOCHANGE  
MULTIQUIP INC.  
Direct TOLL-FREE access  
to our Parts Department:  
Toll-free nationwide — 800-427-1244  
18910 WILMINGTON AVENUE  
POST OFFICE BOX 6254  
CARSON, CALIFORNIA 90749  
310-537-3700 • 800-421-1244  
FAX:310-537-3927  
WWW:multiquip.com  
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — SPECIFICATIONS  
Table 1. Generator Specifications  
DCA-125SSJU/125SSJU2  
Revolving field, self ventilated, drip proof single bearing  
Star with Neutral/Zig Zag  
208, 220, 240, 416, 440, 480V switchable  
120, 127, 139, 240, 254, 277V switchable  
137.5 KVA (110 KW)  
Model  
Type  
Armature Connection  
Voltage 3-Phase  
Voltage Single-Phase  
Standby Output  
Prime Output  
Frequency  
125 KVA (100 KW)  
60 Hz  
1800 rpm  
Speed  
0.8  
Power Factor  
Sound Level dB (A) Full  
Load at 23 feet  
67  
Class F  
Insulation  
Engine Specifications  
JOHN DEERE 6068TF250  
4 Cycle, water-cooled, direct injection, turbo-charged  
6 cylinders  
Model  
Type  
No. of Cylinders  
Bore x Stroke  
Rated Output  
Displacement  
Starting  
(106 mm x 127 mm)  
150 HP/1800 rpm  
410 cu. in. (6724 cc)  
Electric  
10.3 gal. (39 liters)  
Coolant Capacity  
Lube Oil Capacity  
4.5 gal. (17 liters)  
7.5 gal(28.4L)/hr at full load  
4.0 gal(15.1L)/hr at 1/2 load  
5.7 gal(21.6L)/hr at 3/4 load  
2.3gal(8.7L)/hr at 1/4 load  
Fuel Consumption  
12V- 150 AH x1  
#2 Diesel Fuel  
Battery  
Fuel  
PAGE 6 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — DIMENSIONS  
Figure 1. Dimensions  
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS  
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!  
HAZARD SYMBOLS  
Lethal Exhaust Gases  
Engine exhaust gases contain poisonous  
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.  
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.  
This Owner's Manual has been  
developed to provide complete  
instructions for the safe and  
NOTE  
efficient operation of the MQ Power  
Model DCA125SSJU Series  
WHISPERWATT™ GENERATOR.  
Explosive Fuel  
Before using this GENERATOR, ensure that the operating  
individual has read and understands all instructions in this  
manual.  
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.  
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.  
Burn Hazards  
DANGER: You WILL be KILLED or  
SERIOUSLY injured if you DO NOT follow  
directions.  
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.  
WARNING: You CAN be KILLED or  
SERIOUSLY injured if you DO NOT follow  
directions.  
Rotating Parts  
NEVER operate equipment with covers, or  
guards removed. Keep fingers, hands, hair  
and clothing away from all moving parts to  
prevent injury.  
CAUTION: You CAN be injured if you  
DO NOT follow directions.  
Potential hazards associated with trowel operation will be  
referenced with "Hazard Symbols" which appear throughout  
this manual, and will be referenced in conjunction with Safety  
"Message Alert Symbols".  
PAGE 8 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS  
Accidental Starting  
Respiratory Hazard  
ALWAYS place the engine ON/OFF  
switch in the OFF position, when the  
trowel is not in use.  
ALWAYS wear approved respiratory protection.  
Over Speed Conditions  
Sight and Hearing hazard  
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.  
ALWAYS wear approved eye and hearing  
protection.  
Equipment Damage Messages  
This generator, other property, or  
the surrounding environment could  
be damaged if you do not follow  
instructions.  
Other important messages are provided throughout this manual  
to help prevent damage to your trowel, other property, or the  
surrounding environment.  
NOTE  
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — RULES FOR SAFE OPERATION  
NEVER touch the hot exhaust  
manifold, muffler or cylinder. Allow  
these parts to cool before servicing  
engine or generator.  
CAUTION  
:
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.  
The following safety guidelines should always be used when  
operating the DCA-125SSJU Series Generator:  
High Temperatures – Allow the engine to cool before  
performing service and maintenance functions. Contact  
with hot! components  
can cause serious  
burns.  
GENERAL SAFETY  
DO NOT operate or service this equipment  
before reading this entire manual.  
The engine of this  
generator requires an  
adequate free flow of  
cooling air. NEVER  
operate the generator  
in any enclosed or  
This equipment should not be operated by persons under 18  
years of age.  
NEVER operate this equipment without proper  
protective clothing, shatterproof glasses, steel-  
toed boots and other protective devices required  
by the job.  
narrow area where free  
flow of the air is restricted. If the air flow is restricted it will  
cause serious damage to the generator or engine and  
may cause injury to people. The generator engine gives  
off DEADLY carbon monoxide gas.  
ALWAYS make sure generator is properly grounded.  
NEVER use gas piping as an electrical ground.  
NEVER operate this equipment when not feeling  
well due to fatigue, illness or taking medicine.  
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.  
NEVER operate this equipment under the  
influence or drugs or alcohol.  
ALWAYS have a qualified electrician perform the generator  
wiring installation.  
NEVER power cables or cords lay in water.  
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.  
NEVER stand in water while AC power from the generator  
is being transfer to a load.  
NEVER use a defective or frayed power cable. Check the  
Manufacture does not assume responsibility for any accident  
due to equipment modifications.  
cable for cuts in the insulation.  
NEVER use a extension cord that is frayed or damaged where  
the insulation has been cut.  
Whenever necessary, replace nameplate, operation and safety  
decals when they become difficult read.  
ALWAYS make certain that proper extension cord has been  
selected for the job See Table 5.  
ALWAYS check the machine for loosened threads or bolts  
before starting.  
The electrical voltage required to operate the generator can  
cause severe injury or even death through physical contact  
with live circuits. Turn all circuit breakers OFF before  
performing maintenance on the generator.  
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.  
PAGE 10 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — RULES FOR SAFE OPERATION  
.
ALWAYS make sure that electrical circuits are properly  
grounded per the National Electrical Code (NEC) and local  
codes before operating generator.Severe injury or death! by  
electrocution can result from operating an ungrounded  
generator.  
DANGER  
:
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.  
Backfeed to a utility system can cause electrocution and or  
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  
ALWAYS read, understand, and follow  
procedures in Operator’s Manual before  
attempting to operate equipment.  
CAUTION  
:
DANGER  
:
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.  
Never use damaged or worn cables when  
connecting equipment to the generator.  
Make sure power  
c o n n e c t i n g  
cables  
are  
Radiator  
securely connected to the  
generator’s output terminals,  
insufficient tightening of the  
terminal connections may cause  
damage to the generator and  
electrical shock.  
1. Radiator Cap - Removing the radiator cap while the engine  
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.  
2. Coolant Drain Plug - Removing the coolant drain plug  
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.  
WET  
HANDS  
DANGER  
:
NEVER grab or  
touch live  
a
3. Engine Oil Drain Plug - Removing the engine oil drain  
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.  
power cord with  
wet hands , the  
possibility exists  
POWER  
CORD  
(POWER ON)  
of electrical shock, electrocution, and even  
death!  
Maintenance Safety  
DANGER  
:
NEVER lubricate components or attempt service on a running  
machine.  
ALWAYS allow the machine a proper  
amount of time to cool before servicing.  
NEVER touch output terminals during operation. This is  
Keep the machinery in proper running condition.  
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 electrocution, electrical shock or burn,  
which can cause severe bodily harm or even death!  
Fix damage to the machine immediately and always replace  
broken parts.  
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DCA-125SSJU SERIES — RULES FOR SAFE OPERATION  
Battery  
NEVER Run engine without air filter. Severe engine  
damage may occur.  
The battery contains acids that can cause injury to the eyes  
and skin.To avoid eye irritation, always wear safety glasses.  
Use well insulated gloves when picking up the battery. Use  
the following guidelines when handling the battery:  
ALWAYS service air cleaner frequently to prevent engine  
malfunction.  
ALWAYS disconnect the negative battery terminal before  
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.  
1. DO NOT drop the battery. There is the possibility of risk  
DO NOT leave the generator running in the manual mode  
unattended.  
that the battery may explode.  
2. DO NOT expose the battery to  
open flames, sparks, cigarettes  
etc. The battery contains  
combustible gases and liquids. If  
these gases and liquids come in  
contact with a flame or spark, an  
explosion could occur.  
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 John Deere Engine Manual for engine  
technical questions or information.  
3. ALWAYS keep the battery charged. If the battery is not  
DANGER:  
charged a buildup of combustible gas will occur.  
4. ALWAYS keep battery charging and cables in good working  
Pay close attention to  
ventilation when operating  
the generator inside  
tunnels and caves. The  
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.  
engine exhaust contains noxious elements.  
Engine exhaust must be routed to a  
ventilated area.  
6. In case the battery liquid (dilute sulfuric acid) comes in  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
Generator Grounding  
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.  
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.  
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 “Towing Safety Precautions” for  
basic towing techniques.  
ALWAYS be sure to use the ground terminal (green wire)  
when connecting a load to the UVWO output terminals.  
PAGE 12 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)  
Download from Www.Somanuals.com. All Manuals Search And Download.