MQ Power DCA-125USJ Parts Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

ULTRA-SILENT

TM

SERIES

MODEL DCA-125USJ

GENERATOR

PARTS LIST NO. M3870400004

Revision #0 (06/24/04)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

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: [e-mail]
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

© COPYRIGHT 2004, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used,

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
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 Ultra Silent Generator

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

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — 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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

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: [e-mail]
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

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [e-mail]
INTERNET: www.mqpower.com

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — 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)

1

DCA-125USJ — SPECIFICATIONS

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PAGE 6 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

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

Figure 1. Dimensions

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 7

1

DCA85USJ — 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

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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA85USJ — 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

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 9

DCA-125USJ — RULES FOR SAFE OPERATION

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

The following safety guidelines should always be used when
operating the DCA-125USJ 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

r.

PAGE 10 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — 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

or

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

by

■

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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — 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.

1

DCA-125USJ — 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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — 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

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 13

DCA-125USJ — INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide or
shift around. Also install the generator in a manner so that
the exhaust will not be discharged in the direction of nearby
homes.

The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.

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.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 15

DCA-125USJ — 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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — 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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 17

1

DCA-125USJ — GENERATOR DECALS

The DCA-125USJ 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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — GENERATOR DECALS

Figure 4. Generator Decals (Cont.)

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 19

1

DCA-125USJ — GENERAL INFORMATION

DCA-125USJ Series Familiarization
Generator

The MQ Power Model DCA-125USJ is a 100 kW
(Figure 5) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

z

Tachometer

z

Water Temperature Gauge

z

Oil Pressure Gauge

z

Charging Ammeter Gauge

z

Fuel Level Gauge

z

Pre-heat Lamp

z

Panel Light/Panel Light Switch

z

Auto ON/OFF Engine Controller (MPEC)

z

Fuel Leak Detected Alarm Lamp

Generator Control Panel

The “Generator Control Panel” is provided with the following:

z

Frequency Meter (Hz)

z

AC Ammeter (Amps)

z

AC Voltmeter (Volts)

z

Ammeter Change-Over Switch

z

Voltmeter Change-Over Switch

z

Voltage Regulator

z

3-Pole, 300 amp Main Circuit Breaker

Control Box

The “Control Box”, located behind the

Panel

, is provided with the following:

z

Automatic Voltage Regulator

z

Current Transformer

z

Over-Current Relay

z

Voltage Rectifer

z

Starter Relay

z

Engine Controller (Computer Controlled)

z

Voltage Selector Switch

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

z

Three 120/240V output receptacles (CS-6369), 50A

z

Three auxilliary circuit breakers, 50A

z

Two 120V output receptacles (GFCI), 20A

z

Two GFCI circuit breakers, 20A

z

Five output terminal lugs (3Ø power)

z

Battery Charger (Optional)

z

Water Heater (Optional)

Generator Control

generator

Open Delta Excitation System

The DCA-125USJ generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.

When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.

The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load.

Engine

The DCA-125USJ is powered by a 4 cycle, water cooled,
direct injection, turbocharged JOHN DEERE

6068TF275 Diesel Engine

every performance requirement for the generator. Reference
Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.

Electric Governor System

The electric governor system controls the RPMs of the
engine. When the engine demand increases or decreases,
the governor system regulates the frequency variation to
±.25%.

Extension Cables

When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 5) as a guide
for selecting proper extension cable size.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

Model

. This engine is designed to meet

PAGE 20 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — MAJOR COMPONENTS

Figure 5. Major Components

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O

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 21

NOTE PAGE

PAGE 22 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

Figure 6. Generator Control Panel

DCA-125USJ — GENERATOR CONTROL PANEL

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

1. Main Circuit Breaker – This three-pole, 300A main

breaker is provided to protect the the

Terminal Lugs

2. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

3. AC Ammeter – Indicates the amount of current the load

is drawing from the generator per leg selected by the
ammeter phase-selector switch.

4. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.

5. AC Voltmeter – Indicates the output voltage present at

the

U,V, and W Output Terminal Lugs

6. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.

Generator Control Panel

(Figure 6).

U,V, and W Output

from overload.

.

Located behind the generator control panel is the

Control Box

electronic components required to make the generator
function.

The Control Box is equipped with the following major
components:

z

Over-Current Relay

z

Voltage Rectifer (AVR)

z

Starter Relay

z

Current Transformer

z

Voltage Selector Switch

NOTE

In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

load.

Output Terminal Panel

overcurrent

U,V, and W

to the

, press the

main

closed

position (ON).

7. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 23

1

DCA-125USJ — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 24 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENGINE OPERATING PANEL

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

1. Panel Light – Normally used in dark areas or at night

time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control

panel light.

3. Oil Pressure Gauge – During normal operation this

gauge be should read between 35 to 65 psi. When
starting the generator the oil pressure may read a little
higher, but after the engine warms up the oil pressure
should return to the correct pressure range.

4. Water Temperature Gauge – During normal operation

this gauge be should read between 180° and 221°F.

5. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.

8. Pre-Heat Lamp – As the engine cranks, this lamp will

illuminate to indicate automatic preheating of the engine.
When the lamp turns off, the engine has been preheated
and will start automatically.

9. Fuel Leak Detected Alarm Lamp – This lamp will

illuminate when a leak in the fuel tank containment
enclosure is detected.

10. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical
row of status LED's (inset), that
when lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has
been detected the engine
controller will evaluate the fault
and all major faults will
shutdown the generator.

Engine Operating Panel

(Figure 7).

During
engine for 10 seconds before disengaging. If the engine does
not engage (start) by the third attempt, the engine will be
shutdown by the engine controller’s
mode. If the engine engages at a speed (RPM's) that is not
safe, the controller will shutdown the engine by initializing
the

Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup. These conditions
can be observed by monitoring the LED status indicators on
the front of the controller module.

A. MPEC Control Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure has

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has

E. Overspeed Shutdown – Indicates the engine is running

F. Engine Running – Indicates that engine is running at

cranking cycle

Over Speed Protection

running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.

If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the AUTO position. In this position the
generator will monitor the AC line output from the
building's power source.

fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a

temperature has exceeded 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

major

fault.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 25

DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
lugs.

NOTE

(Figure 8) shown below is located

Terminal legs “O” and “Ground” are
considered

bonded grounds

Output Terminal Familiarization

The “

Output Terminal Panel

following:

z

Three (3) 120/240V output receptacles @ 50 amp

z

Three (3) Circuit Breakers @ 50 amps

z

Two (2) 120V GFCI receptacles @ 20 amp

z

.

Two (2) GFCI Circuit Breakers @ 20 amps

z

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 — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
position. Each receptacle is protected by a 20 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) of both
GFCI receptacles is dependent on the load requirements of
the UVWO terminals.

Pressing the
being tripped. Pressing the "
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

" (See Figure 9) in

Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will

Figure 11. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.

.

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

(Figure 11) on the

After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 10) provided on the output
terminal panel.These receptacles can
when the voltage selector switch is placed in the

only

be accessed

single-

phase 240/120 position.

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 27

1

DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Lugs

or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.

To protect the output terminals from overload, a

main

3-pole, 300A
switch ALL circuit breakers to the OFF position prior to
starting the engine.

circuit breaker is provided. Make sure to

Ouput Terminal

Blower Fan

This unit has an intake fan located at the rear of the machine
to draw outside air into the cabinet to cool the engine. The
fan has a 10 amp AC fuse located beneath the

Selector Switch

DANGER:

Figure 13. Connecting Loads

Over Current Relay

An

over current relay

circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
rent relay must be pressed. The over current relay is lo­cated in the control box.

(Figure 14) is connected to the main

reset button

on the over cur-

replace the fuse with the engine
and/or generator operating could
result in

bodily harm

unit completely off before
attempting to replace or handle

THIS fuse

electrocution

Voltage

(Figure 15).

Figure 15. Blower Fan Fuse

This fuse has current running through it any
time the engine is operating.
IS NOT connected to the main circuit
breaker OF the generator. Attempting to

and

severe

. ALWAYS turn the

THIS FUSE

Figure 14. Over Current Relay

PAGE 28 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage,

frequency

Three Phase Load

When calculating the power requirements for 3-phase power
use the following equation:

,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

If wattage is not given on the
equipment's name plate,

NOTE

approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 4 below
when connecting loads.

An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out

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When connecting a resistance load such as an
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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 connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.

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When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.

DANGER:

If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.

Motors and motor-driven
equipment draw much greater
current for starting than during
operation.

Before connecting this generator to any
building’s electrical system, a

electrician
(transfer) switch

must install an

. Serious damage to the

licensed

isolation

building’s electrical system may occur
without this transfer switch.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 29

DCA-125USJ — GENERATOR OUTPUTS

Voltage Selector Switch

voltage selector

The
the output terminal panel’s

switch (Figure 16) is located above

Hard Wire Hook-up Panel

Generator Amperage

Table 7 describes the generator’s current output capability

. It

for both 1Ø-phase and 3Ø phase applications.

has been provided for ease of voltage selection.

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly re­lated to the voltage being supplied at either the output termi­nals or the 3 twist lock auxilliary receptacles.

Tables 8 and 9 show what amount of current is available at
the GFCI receptacles when the output terminals and twist

Figure 16. Voltage Selector Switch

Voltage Selector Switch Locking Button

lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep­tacles.

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,

hold

the

red button

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

located at the bottom of the switch.

NEVER change the position of the

selector switch

while the engine is running.

press

voltage

and

ALWAYS place circuit breaker in the open
position before selecting voltage.

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Generator Output Voltages

A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the

voltage selector

switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a
fine adjustment using the

knob

located on the control panel.

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PAGE 30 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

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DCA-125USJ — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied at the

Output terminals lugs

Before taking a reading off either gauge, set the

Selector Switch

the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the volt­age selector switch.)

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

.

Voltage

(Figure 17) to the position which produces

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 20) to activate the
(Figure 21) and read the available amperage at the terminal
lug.

For example, to measure the amperage at the U
terminal lug, set the
U and read the AC Ammeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Figure 21. AC Ammeter
(Amp reading on U lug)

to

For 3Ø 208V/1Ø,120V, place

NOTE

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch

setting (Figure 18) to activate the
(Figure 19) and read the available voltage between the two
lugs.

For example, to measure the voltage between the W and U
terminal lugs, set the
to W-U and read the

AC Voltmeter Change-Over Switch

AC Voltmeter Gauge

the Voltage Selector Switch
in the 3 Phase 340/139
position.

to the appropriate

AC Voltmeter Gauge

.

NOTE

The

ammeter

show a reading when the

Output Terminal Lugs

connected to a load and in use.

gauge will only

are

Figure 18. AC Voltmeter

Change-Over Switch

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 31

Figure 19. AC Voltmeter Gauge

(Volt reading on W-U Lug)

1

DCA-125USJ — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the

Terminal Lugs

dent on the position of the
adjustment of the

Remember the voltage selector switch determines the
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.

.. The voltages at the terminals are depen-

Voltage Selector Switch

Voltage Regulator Control Knob

Output

and the

.

range

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 25.

2. Connect the load wires to the
shown in Figure 26.

Use this position for
3Ø-208 or 1Ø120V.

Figure 25. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position

Output Terminal Lugs

as

Figure 22. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the
shown in Figure 22.

Figure 23. Output Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

Output Terminal Lugs

as

Figure 26. Output Terminal Lugs

3Ø-208V/120V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

To achieve a 3Ø 208V output
the voltage selector switch

NOTE

must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.

Figure 24. Voltage Regulator Knob (139V/240V)

PAGE 32 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the
shown in Figure 28.

Output Terminal Lugs

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 29.

Figure 29. Voltage Selector Switch 240/120V

as

2. Connect the load wires to the
shown in Figure 30.

Single-Phase Position

Output Terminal Lugs

as

Figure 28. UVWO Terminal Lugs

480/277V Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 33

Figure 30. UVWO Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

1

DCA-125USJ — PRE-SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 110 amp,

DANGER:DANGER:

DANGER:

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

DANGER:DANGER:

breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 31) on the dipstick. See Table 10 for proper

Refilling the Fuel System

selection of engine oil.

WARNING:WARNING:

WARNING:

WARNING:WARNING:

Figure 31. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the John Deere Engine Owner's Manual. Oil should be
warm before draining.

Other types of motor oils may be substituted if they meet
the following requirements:

The generator unit has an internal fuel tank located at the
bottom of the cabinet (Figure 32).
with clean and fresh
tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel

z

API Service Classification CC/SC

z

API Service Classification CC/SD

z

API Service Classification CC/SE

z

API Service Classification CC/SF

Table 10. Recommended Motor Oil

30

OIL: SAE

10W/40

5W30

ARCTIC OIL

122

104

86

68

50

-14

-22

-40

F

C

50

40

30

20

10

10W40

032

-10

-20

-4

-30

-40

15W30

10W30

20W40

10W

immediately.

Figure 32. Internal Fuel Tank System

Fuel spillage on a

fire

or

explosion

hot!

engine can cause a

. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards.

NEVER!

smoke

around or near the generator.

ONLY properly trained personel who have
read and understand this section should re­fill the fuel tank system.

ALWAYS

#2 diesel fuel.

fill the fuel tank

DO NOT fill the fuel

PAGE 34 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — PRE-SETUP

Refueling Procedure:

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Diesel fuel

to your health and the surrounding
environment. Avoid skin
contact and/or inhaling
fumes.

1. Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 33).

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALWAYS!

before refueling.

and its vapors are dangerous

place trailer on firm level ground

3. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel cap
and fill tank (Figure 34).

Figure 34. Fueling the Generator

3. NEVER overfill fuel tank – It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait for
fuel to rise in filler neck (Figure 35).

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

when

Figure 35. Full Fuel Tank

WARNING:WARNING:

WARNING:

WARNING:WARNING:

DO NOT OVER-FILL fuel system. Leave
room for fuel expansion . Fuel expands when
heated (Figure 36).

Figure 36. Fuel Expansion

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 35

Coolant (John Deere Antifreeze/Summer Coolant/Water)

DCA-125USJ — PRE-SETUP

John Deere recommends John Deere Antifreeze/Summer
Coolant for use in thier engines, which can be purchased in
concentrate (and mixed with 50% demineralized water) or
pre-diluted. See the John Deere Engine Owner's Manual
for further details.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

If adding coolant/antifreeze mix to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. The
possibility of
burns.

Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 11 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.

hot!

coolant exists which can cause severe

yticapaCtnalooC.11elbaT

NOTE

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
dangerous, so clean only with the engine turned off and the

negative

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 37) when depressed with the thumb as shown
below.

When the antifreeze is mixed with
water, the antifreeze mixing ratio

must be

battery terminal disconnected.

less than 50%.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.

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Figure 37. Fan Belt Tension

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

NEVER!

near the belts or fan while
the generator set is
running.

place hands

PAGE 36 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.

Before charging the battery with an external electric source,
be sure to disconnect the battery cables.

Battery Cable Installation
ALWAYS be sure the battery cables (Figure 38) are properly

connected to the battery terminals as shown below. The

RED

cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Always

keep the terminals firmly tightened.

:

ALWAYS

FIRST and reconnect negative terminal
LAST.

disconnect the negative terminal

When connecting battery do the following:

1. NEVER connect the battery cables to the battery
terminals when the
the MANUAL position. ALWAYS make sure that the

MPEC Control Switch

when connecting the battery.

2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will ensure
a good connection and will help prevent corrosion around
the battery terminals.

NOTE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Alternator

The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.

Wiring

MPEC Control Switch

is in the OFF/RESET position

If the battery cable is connected

incorrectly, electrical damage to
the generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.

is in either

:

Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.

Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring 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 clamps and check hoses
for leaks.

If any hose (
immediately.

Figure 38. Battery Connections

fuel

or

oil

) lines are defective replace them

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 37

DCA-125USJ — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.

ventilation when operating

away from nearby personnel.

Before Starting

ALWAYS have adequate

CAUTION:

NEVER!
main, GFCI

the ON (closed) position.

1. Place the
in the OFF position prior to starting the engine.

main, G.F.C.I.

manually start the engine with the

or

and

auxiliary

aux.

circuit breakers in

circuit

breakers (Figure 39)

. Direct exhaust

4. Close all engine enclosure doors (Figure 40).

Figure 40. Engine Enclosure Doors

5. Place the
in the desired voltage position
(Figure 41).

Figure 41. Voltage Selector

voltage selector switch

Switch

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the

Terminal Lugs

connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.

3. The output terminal lugs 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.

as shown in Figure 13. These load

PAGE 38 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

receptacles or

the

Output

DCA-125USJ — GENERATOR START-UP PROCEDURE (MANUAL)

Starting (Manual)

8. Place the

position to start the engine (Figure 42).

In cold weather conditions, placing the

Switch

the engine AUTOMATICALLY. The
(Figure 43) will turn off when the engine has started.

7. Once the engine starts, let the engine run for 1-2 minutes.

Listen for any abnormal noises.

MPEC Control Switch

Figure 42. MPEC Control Switch

(Manual Position)

in the MANUAL

MPEC Control

in the MANUAL position will preheat and start

Preheat Lamp

9. The generator's frequency meter (Figure 45) should be
displaying the 60 cycle output frequency in HERTZ.

Figure 45. Frequency Meter (Hz)

10. The generator's AC-voltmeter (Figure 46) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 47) to increase or decrease the
desired voltage.

Figure 43. Pre-Heat Lamp

8. Verify that the Engine Running
status LED on the MPEC unit
(Figure 44) is ON (lit) after the
engine has been started.

Figure 44. Engine Running

LED (ON)

Figure 46. Voltmeter

Figure 47. Voltage Adjust Control Knob

11. The ammeter (Figure 48) will
indicate zero amps with no load
applied. When a load is applied,
the ammeter will indicate the
amount of current that the load is
drawing from the generator.

Figure 48. Ammeter (No Load)

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 39

DCA-125USJ — GENERATOR START-UP PROCEDURE (MANUAL)

12. The engine oil pressure gauge
(Figure 49) will indicate the oil
pressure (kg/ cm2) of the engine.
Under normal operating conditions
the oil pressure is approximately
35~65 PSI.

Figure 49. Oil Pressure Gauge

13. The

coolant temperature gauge

(Figure 50) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (

Figure 50. Coolant Temperature Gauge

14. The

tachometer gauge

(Figure 51) will indicate the

Green Zone

).

speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.

15. Place the

main, GFCI

, and

aux

. circuit breakers in the

ON position (Figure 52).

Figure 52. Main, Aux. and GFCI

Circuit Breakers (ON)

16. Observe the generator's ammeter (Figure 53) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if a load is in use.

Figure 51. Engine Tachometer Gauge

PAGE 40 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

Figure 53. Ammeter (Load)

17. The generator will run until manually stopped or an
abnormal condition occurs.

DCA-125USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

DANGER:

Before connecting this
generator to any
building’s electrical
system, a

electrician

Serious damage to the building’s electrical system may occur
without this transfer switch.

must install an

licensed

isolation (transfer) switch

.

CAUTION:

When connecting the generator to a
isolation (transfer) switch, ALWAYS have
power applied to the generator's internal
battery charger. This will ensure that the
engine will not fail due to a dead battery.

When the generator is set in the

AUTO mode, the generator will

NOTE

automically start

of comercial power falling below
a prescribed level by means of
a contact closure that is
generated automatically by a
transfer switch.

in the event

Starting (Auto Mode)

2. Place the

AUTO position .

Figure 54. MPEC Control Switch (AUTO)

3. Continue to follow the steps outlined in the

up

procedure (start at step 9).

MPEC Control Switch

(Figure 54) in the

Manual Start-

WARNING:

When running the generator in the AUTO
mode, remember the generator can start
up at any time without warning. NEVER
attempt to perform any maintenance when
the generator is in the auto mode.

1. Perform steps 1 through 5 in the
as outlined in the

Manual Starting Procedure

Before Starting

section

.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 41

DCA-125USJ — GENERATOR SHUT-DOWN PROCEDURE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 39 to the OFF position.

3. Let the engine cool by running it for 3-5 minutes with no
load applied.

4. Place the

OFF/RESET position.

:

NEVER stop the engine suddenly except

in an emergency. DO NOT use the
emergency stop switch a as method of
shutting down the generator. This switch is
ONLY to be used in the event of an
emergency.

MPEC Control Switch

(Figure 55) to the

Emergency Shutdown Procedure

1. To shut-down the engine in the event of an emergency,
switch the
breakers to OFF position.

2. Place the
the OFF/RESET position.

MAIN, GFCI

MPEC Control Switch

and

LOAD

(Figure 39) circuit

switch (Figure 55) to

Figure 55. MPEC Control Switch (Off/Reset)

5. Verify that the
are OFF (not lit).

6. Remove all loads from the generator.

all

status LED on the MPEC display

PAGE 42 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — MAINTENANCE

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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.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.

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 meaning the element needs
changing or service. After changing the air element, press the
dust indicator button to reset the indicator.

Service Daily

If the engine is operating in very
clogged air cleaner will result. This can lead to a loss of power,
excessive carbon buildup in the combustion chamber and high
fuel consumption. Change air cleaner more
conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and
locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in
the bottom of the tank. Occasionally inspect the fuel tank for
water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank,
the easier it is for water to condense. This can be reduced by
keeping the tank full with diesel fuel.

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 43

dusty

or

dry grass

frequently

conditions, a

if these

1

DCA-125USJ — MAINTENANCE

Air Removal

If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure. See the

Engine Manual

Check Oil Level

Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 33.

Replacing Oil Filter

Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.

for details.

John Deere

Flushing Out Radiator and Replacing Coolant

z

Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open the
radiator cap while draining. Remove the overflow tank
and drain.

z

Check hoses for softening and kinks. Check clamps for
signs of leakage.

z

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.

z

Tighten both cocks and replace the overflow tank.

z

Replace with coolant as recommended by the engine
manufaturer.

z

Close radiator cap tightly.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Allow engine to
radiator. Flushing the radiator while hot could
cause serious burns
from water or steam.

cool

when flushing out

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500
hours or so.

Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.

Vent any air.

Generator Storage

For longe term storage of the generator the following is
recommended:

z

Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.

z

Completely drain the oil from the crankcase and refill if
necessary with fresh oil.

z

Clean the entire generator, internal and external.

z

Cover the generating set and store in a clean, dry place.

z

Disconnect the battery.

z

Make sure engine coolant is at proper level.

z

If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.

PAGE 44 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — MAINTENANCE

Jacket Water Heater and Internal Battery Charger
120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,
20 amp input receptacles located on the output terminal
panel.

The purpose of these receptacles is to provide power via
commercial power to the

battery charger

These receptacles will ONLY function when commercial
power has been supplied to them (Figure 56). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 5).

When using the generator in
to apply power to jacket water heater. However, if the
generator will be used in
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.

.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.

NOTE

To ensure adequate starting
capability, always have power
applied to the generator's

internal battery charger

.

Figure 56. DCA-45SIU2 Battery Charger &

Jacket Water Heater Power Connections

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 45

DCA-125USJ — TRAILER BRAKES MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat
properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 57) should not require any

of

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.

brakes more frequently.
Figure 60 displays the major hydraulic surge brake

components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

Figure 57. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake
shoes.

5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.

Actuator

Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer

6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to
the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.

Periodically check and test the surge “
sure that it is functioning correctly. Never use an undersize
actuator.

surge

or

actuator

” to make

push

of

gnitoohselbuorTekarBciluardyH.41elbaT

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

?dezalggninilekarB.ecalpe

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

eriT.yllauqeseritllaetalfnI

opmocekarB.stnenopmocecalpeR

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserp

?elxaemasehtnodehctamnuseriT.serithctaM

?nekorbrotneb,esoolstnen

?dnuor-fo-tuosmurdekarB.ecalpeR

?detacirbulmetsyS.etacirbuL

?tcerro

cstnenopmocekarB.tcerrocdnaecalpeR

tonrotcerrocnissenkcihtgninilekarB

?yltcerrocdetsujda

?diulftcerrocrodiulfekarbhguonE

rrohsinrubeR

dn

aseohswenllatsnI

.sgninil

straprebburecalpeR

.diulf4todhtiwllif

PAGE 46 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.

Suspension

leaf suspension

The
(Figure 58) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components

CAUTION:

as detailed in Table 16.

DO NOT attempt
to repair or
modify a wheel.

DO NOT install in
inner tube to correct a leak through the rim. If the rim is
cracked, the air pressure in the inner tube may cause pieces
of the rim to explode (break off) with great force and cause
serious eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are

hot!

. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.

Figure 58. Major Suspension Components

springs and associated components

Table 15 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.

TABLE 15. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber
or overloading.

Wheel lockup &
tire skidding.

SOLUTION

Adjust pressure to
particular load per tire
manufacturer.

Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.

Check bearing adjustment
and balance tires.

Avoid sudden stops when
possible and adjust brakes.

CAUTION:

ALWAYS

or installing force fitted parts. Failure to comply
may result in serious injury.

wear safety glasses when removing

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

stnemeriuqeReuqroTnoisnepsuS.61elbaT

.

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

PARTS MUST ROTATE FREELY

-

BOLT ASSEMBLY

.

05-XAM03-NIM

.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 47

DCA-125USJ — TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 59). DO NOT
torque the wheel lug nuts all the way down. Tighten each
lug nut in 3 separate passes as defined by Table 17.

3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.

stnemeriuqeReuqroTeriT.71elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"3

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 59. Wheel Lug Nuts

Tightening Sequence

NEVER

NOTE

PAGE 48 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

gun to tighten wheel lug nuts.

use an pneumatic air

DCA-125USJ — TRAILER WIRING DIAGRAM

Figure 60. Trailer/Towing Vehicle Wiring Diagram

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 49

DCA-125USJ — GENERATOR WIRING DIAGRAM

Figure 61. Generator Wiring Diagram

PAGE 50 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENGINE WIRING DIAGRAM

Figure 62. Engine Wiring Diagram

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 51

1

DCA-125USJ — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 18 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.

GNITOOHSELBUORTROTARENEG.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 52 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 (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 office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve

)dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

.

nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

?ytridpukcipci

?detarbilacebotsdeenrellortnoCenign

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

sujdA

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 53

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number
range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model number
or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column,
or <, belong to the same assembly or kit

If more than one of the same

NOTE

NOTE

reference number is listed, the last
one listed indicates newest (or
latest) part available.

The contents of this catalog are
subject to change without notice

, #, +, %,

*

.

PAGE 54 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — SUGGESTED SPARE PARTS

DCA-125USJ W/JOHN DEERE

4045TF275 DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

5 .............. 0602041292 ........................FILTER, OIL

5 .............. 0602042594 ........................FILTER, FUEL, PRIMARY

5 .............. 0602042595 ........................FILTER, FUEL, FINAL

3 .............. 0602046377 ........................ELEMENT, AIR

1 .............. 0602011493 ........................BELT, FAN

1 .............. 0605505070 ........................CAP. FUEL TANK

1 .............. 0602122272 ........................UNIT, OIL PRESSURE

1 .............. 0602123261 ........................UNIT, WATER TEMPERATURE

2 .............. 0601802149 ........................FUSE, 10A

1 .............. 0602123282 ........................SENDER, WATER SWITCH (ENGINE SIDE)

1 .............. 0602122281 ........................SENDER, OIL SWITCH (ENGINE SIDE)

1 .............. 060122272 ..........................UNIT, OIL PRESSURE

1 .............. 0602123261 ........................UNIT, WATER TEMPERATURE

Part number on this Suggested Spare Parts

NOTE

list may supercede/replace the P/N shown
in the text pages of this book.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 55

GENERATOR ASSY.

DCA-125USJ — GENERATOR ASSY.

PAGE 56 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0110000002 ROTOR ASSY. 1
1-1

*

1-2*8131070013 FAN 1
1-3*8131611014 COUPLING DISK 8

1-4*8131015003 BALANCING PLATE ............................................1 ............. PURCHASE SET OF 1-14

1-5*0012112035 HEX HEAD BOLT 10
1-6*0042612000 SPRING WASHER 10

1-7*8101026013 SET PLATE, RECTIFIER .................................... 1 ............. PURCHASE SET OF 1-14

1-8*0601821349 RECTIFIER ......................................................... 2 ............. PT3610

1-9*0601822601 SURGE ABSORBER ...........................................1 ............. ERZ-M14JK621A

1-10*8001020004 INSULATOR WASHER 1
1-11*8001020504 INSULATOR WASHER 1
1-12*0010110020 HEX, HEAD BOLT 4
1-13*0040010000 SPRING WASHER 4
1-14*0601000209 BALANCING WEIGHT KIT 1

1-15*0071906312 BEARING ............................................................1 ............. 6312DDUC3

2 C0130000503 STATOR ASSY. 1
3 0845041804 GROMMET 2
4 8131315202 END BRACKET 1
5 8101350013 FIELD ASSY. EXCITER 1
6 0012110060 HEX, HEAD BOLT 4
7 0042610000 SPRING WASHER 4
8 0041210000 PLAIN WASHER 4
9 0010112035 HEX, HEAD BOLT 6
10 0041212000 SPRING WASHER 6
11 0041212000 PLAIN WASHER 6
12 8131310104 COVER, BEARING 1
13 8131312204 GASKET, BEARING 1
14 8131331003 COVER, END BRACKET 1
15 0017106012 HEX, HEAD BOLT 10
16 8101333003 COVER, END BRACKET 1
17 0010106030 HEX, HEAD BOLT 2
18 0040006000 SPRING WASHER 2
19 0041206000 PLAIN WASHER 2
20 M3163400003 COUPLING RING 1
21 0343204150 HEX, HEAD BOLT 8
22 0043604000 SPRING WASHER 8
23 0070506306 BEARING, 6306ZZ 1
24 0012810030 HEX, HEAD BOLT 12
25 0012810030 HEX, HEAD BOLT 12
26 8131332014 COVER, FAN 1
27 0600815000 NUT 1
28 0605000063 RUBBER SUSPENSION, KA120SS 2
29 0030016000 HEX, NUT 2
29A 0040016000 SPRING WASHER 2

FIELD ASSY. 1

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 57

CONTROL BOX ASSY.

DCA-125USJ — CONTROL BOX ASSY.

PAGE 58 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3213000702 CONTROL BOX 1
2 0330000180 EDGING 2

3 0601808823 CIRCUIT BREAKER, 300A ............................... 1 ........... LAF3630010393P

4 0021006080 MACHINE SCREW 4

5 0601823863 RELAY UNIT ..................................................... 2 ........... MSA9013A

6 0027104016 MACHINE SCREW 4

7 0601820671 AUTOMATIC VOLTAGE REGULATOR................ 1 ........... NTA-5A-2DB

8 0027105016 MACHINE SCREW 4

9 0601806118 CURRENT TRANSFORMER ............................. 3 ........... 814-943 200/5A

10 0027106016 MACHINE SCREW 6

11 0601820845 OVER CURRENT RELAY .................................. 1 ........... LR2D1308

12 0601820846 OVER CURRENT RELAY .................................. 1 ........... LA7D1064

13 0027104016 MACHINE SCREW 2
13A 0207004000 HEX, NUT 2
14 M3213500013 CONTROL BOX COVER 1
15 0016906016 HEX, HEAD BOLT 4

16 M3270100104 SELECTOR SWITCH ........................................ 1 ........... XUSS01574

16A 047230402 KNOB, SELECTOR SWITCH 1
17 M3276600004 SPACER 8
18 M3213600503 SWITCH BRACKET 1
19 03300003330 EDGING 2
20 0027104010 MACHINE SCREW 4
21 0016906016 HEX, HEAD BOLT 6
22 M3213600604 SWITCH COVER 1
23 0016906016 HEX, HEAD BOLT 4
24 0016906016 HEX, HEAD BOLT 10
24A 0040506000 TOOTHED WASHER 1
25 M3223000503 CONTROL PANEL 1

26 0601807641 FREQUENCY METER ...................................... 1 ........... FCF-6 45~65Hz 240V

27 0601808988 AC AMMETER .................................................. 1 ........... ACF-6 0~200A/400A:5A

28 0601801040 CHANGE-OVER SWITCH, AMMETER ............. 1 ........... SL-2AS

29 0601806859 AC VOLTMETER ............................................... 1 ........... SCF-6 0~600V

30 0601801041 CHANGE-OVER SWITCH, VOLTMETER .......... 1 ........... SL-2VS

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 59

CONTROL BOX ASSY.

DCA-125USJ — CONTROL BOX ASSY.

PAGE 60 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

31 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ............... 1 ........... RA20A2SE102BJ 2W 1k OHM

32 0601840121 KNOB 1

33 ECU9988NJD CONTROLLER .................................................. 1 ........... REPLACES 0602202593

34 0601831340 SWITCH ............................................................ 1 ........... 7562K4

35 0027104040 MACHINE SCREW 2
35A 0207004000 HEX, NUT 2

36 0602103092 PREHEAT LAMP ............................................... 1 ........... PL-05

36A 0601810245 BULB 1

37 0602120096 TACHOMETER .................................................. 1 ........... 111812

38 0602122093 OIL PRESSURE GAUGE .................................. 1 ........... 100174

39 0602123092 WATER TEMPERATURE GAUGE ..................... 1 ........... 100182

40 0602121080 CHARGING AMMETER .................................... 1 ........... 100158

41 0602125090 FUEL GAUGE .................................................... 1 ........... 100176

42 0601810141 PANEL LIGHT .................................................... 1 ........... 8826800370

43 0601831330 SWITCH, PANEL LIGHT ................................... 1 ........... 90-0001

44 M1223100004 STOPPER 1
45 M3223100004 STOPPER 1
46 0027105010 MACHINE SCREW 4
47 0027105010 MACHINE SCREW 4
48 M9220100004 SET SCREW 2
49 0080200007 SNAP RING 2

50 0602202592 STARTER RELAY .............................................. 1 ........... AT141011

51 0027106018 MACHINE SCREW 2
52 LY2DDC12V RELAY 1
52A PTF08A BASE 1
52B PYCA1 CLIP 2
53 0027104020 MACHINE SCREW 2

54 0601823240 RECTIFIER ....................................................... 1 ........... DE4503

57 0602122272 UNIT, OIL PRESSURE ...................................... 1 ........... 108497

57A M9200100004 ADAPTOR 1

58 0602123261 UNIT, WATER TEMPERATURE ......................... 1 ........... 02025-00

58A 0602021109 PACKING 1
60 M3246701904 WIRE HARNESS, GENERATOR 1
61 M3357201102 WIRE HARNESS, ENGINE 1

62 M3357200304 WIRE HARNESS, FUEL LEAK ......................... 1 ........... 8400041~

63 0601802149 FUSE ................................................................. 2 ........... F-106510A

64 0601823240 RECTIFIER ....................................................... 1 ........... DE4503

65 0602103092 ALARM LAMP, PL095 ........................................ 1 ...........

65A 0601810245 BULB ................................................................. 1 ........... 8400041~

8400041~

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 61

ENGINE AND RADIATOR ASSY.

DCA-125USJ — ENGINE AND RADIATOR ASSY.

PAGE 62 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3923200054 ENGINE & RADIATOR SET ................................. 1 ........ JOHN DEERE 6068TF275

1-1 0602041292 CARTRIDGE, OIL FILTER .................................... 1 ........ RE504836

1-2 0602042594 CARTRIDGE, PRIMARY, FUEL FILTER ............... 1 ........ RE517181

1-3 0602042595 CARTRIDGE, FINAL, FUEL FILTER .................... 1 ........ RE509031

1-4 0602011493 FAN BELT ............................................................. 1 ........ 2402

2 0602060003 BLOWER FAN ......................................................1 ........ AT39247

3 0602061000 FAN SPACER ....................................................... 1 ........ R81911

4 0012110095 HEX, HEAD BOLT 4
5 0042510000 SPRING WASHER 4
6 M2303200303 ENGINE FOOT 2
7 0010312030 HEX, HEAD BOLT 6
8 0040012000 SPRING WASHER 6
9 0605000060 RUBBER SUSPENSION 2
10 0030012000 HEX, NUT 2
11 0040012000 SPRING WASHER 2
12 C0923200124 RADIATOR 1
12A 0602011062 CAP, RADIATOR 1
13 M9200100904 PLUG 1
14 0150000016 O RING 1
15 M3131300103 FAN BRACKET 1
16 0016910025 HEX, HEAD BOLT 6
17 0016910025 HEX, HEAD BOLT 4
18 M3310500813 RADIATOR HOSE 1
19 M3310500903 RADIATOR HOSE 1
20 0605515148 HOSE BAND 3
21 0605515147 HOSE BAND 1
22 0601822794 FAN MOTOR 2
23 0017110035 HEX, HEAD BOLT 8

24 0602046258 AIR CLEANER .....................................................1 ........ FRG100297

24A 0602046377 ELEMENT, AIR CLEANER ...................................1 ........ P778214

25 0602040650 INDICATOR, AIR CLEANER ................................. 1 ........ RBXO0-2252

26 0602040596 BAND, AIR CLEANER 2
27 0016908020 HEX, HEAD BOLT 4
28 0207008000 HEX, NUT 4
29 M3373100003 HOSE, AIR CLEANER 1
30 0605515146 HOSE BAND 1

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 63

ENGINE & RADIATOR ASSY.

DCA-125USJ — ENGINE AND RADIATOR ASSY.

PAGE 64 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

31 0605515197 HOSE BAND 1
32 0602022563 ADAPTER 1
33 0602022561 90 DEGREE ELBOW 1
34 0603306590 CONNECTOR 1
35 0603300285 ROCKNUT 1
36 0605511395 VALVE 1
37 0603306395 HOSE JOINT 1
38 0602021070 CAP 1
39 0269200450 DRAIN HOSE 1
40 M9300000203 RESERVE TANK 1
41 0602010900 CAP, RESERVE TANK 1
42 M3316100303 BRACKET, RESERVE TANK 1
43 0016908020 HEX, HEAD BOLT 3
44 0199102200 HOSE 1
45 0193600700 HOSE 1
46 0193601000 HOSE 1
47 0605515106 HOSE BAND 3
48 M3326000204 BLOWBY HOSE 1
49 0605515149 HOSE BAND 1
50 M3260600104 RELAY BRACKET 1

52 0602202592 RELAY ............................................................... 1 ........... AT141011

53 0027106016 MACHINE SCREW 2
54 0030006000 HEX, NUT 2
55 0017112025 HEX, HEAD BOLT 1
56 0040512000 TOOTHED WASHER 1
57 0602122281 SENDER, OIL PRESSURE 1
58 0602123282 SENDER, WATER PRESSURE 1

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 65

OUTPUT TERMINAL ASSY.

DCA-125USJ — OUTPUT TERMINAL ASSY.

PAGE 66 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3230700003 TERMINAL PANEL 1
2 M9220100304 OUTPUT TERMINAL BOLT 5
3 M9220100404 TIE BOLT 5
4 0039316000 HEX, NUT 10
5 0040016000 SPRING WASHER 15
6 0041416000 PLAIN WASHER 20
7 0016908035 HEX, HEAD BOLT 5
8 M3236100503 TERMINAL COVER 1
9 M3236100404 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0027103010 MACHINE SCREW 4
11A 0030003000 HEX, NUT 4
11B 0041203000 PLAIN WASHER 4
12 0027103010 MACHINE SCREW 4
12A 0030003000 HEX, NUT 4
13 0016906020 HEX, HEAD BOLT 2
14 0016906016 HEX, HEAD BOLT 4
15 M3236400004 CABLE OUTLET COVER 1
16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1
17 0016906020 HEX, HEAD BOLT 6

18 0601808803 CIRCUIT BREAKER, 1-POLE 20A .................... 2 ........... QOU 120B

19 0601808804 CIRCUIT BREAKER, 2-POLE 50A .................... 3 ........... QOU 250B

20 M1260700304 BREAKER FITTING COVER 1
20A 022100150 CUSHION RUBBER 1
21 0016906020 HEX, HEAD BOLT 2

22 0601812598 RECEPTACLE ................................................... 2 ........... GF530EM 125V 20A X 2

23 0601812538 RECEPTACLE ................................................... 3 ........... CS6369 250V 50A

24 0027104016 MACHINE SCREW 10
24A 0207004000 HEX, NUT 10
25 M3236100213 TERMINAL COVER 1
26 0010112045 HEX, HEAD BOLT 2
27 0041212000 PLAIN WASHER 2
28 M9310200004 STAY RUBBER 2
29 0030012000 HEX, NUT 2
30 0603306775 BLIND PLUG 2
31 0027104016 MACHINE SCREW 4
32 0601815194 TERMINAL 1
33 0027104016 MACHINE SCREW 2

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.

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 67

BATTERY ASSY.

DCA-125USJ — BATTERY ASSY.

PAGE 68 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220196 BATTERY ....................................................... 1 ............. 4D-2

2 M9310500404 BATTERY SHEET 1
3 M9103000504 BATTERY BAND 1
4 0602220921 BATTERY BOLT SET 2
5 M3346900904 BATTERY CABLE 1
6 M3346901004 BATTERY CABLE 1

7 CABLE ........................................................... 1 ............. MAKE LOCALLY

8 0030012000 HEX, NUT 1
8A 0040012000 SPRING WASHER 1
9 0017112025 HEX, HEAD BOLT 1
9A 0040512000 TOOTHED WASHER 1
10 0040520000 TOOTHED WASHER 1

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 69

MUFFLER ASSY.

DCA-125USJ — MUFFLER ASSY.

PAGE 70 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3330100402 MUFFLER 1
2 0017112030 HEX, HEAD BOLT 4
3 M3333000903 EXHAUST PIPE 1
4 M3333200304 GASKET 1
5 0017110040 HEX, HEAD BOLT 4
6 M3333200204 GASKET 1
7 0017108040 HEX, HEAD BOLT 4

7 0017110035 HEX, HEAD BOLT ............................................. 4 ........... S/N 8500015~

8 M3333000803 EXHAUST PIPE 1
9 0016908055 HEX, HEAD BOLT 4

9 0017110050 HEX, HEAD BOLT ............................................. 4 ........... S/N 8500015~

10 0602325066 CLAMP 1

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 71

FUEL TANK ASSY.

DCA-125USJ — FUEL TANK ASSY.

PAGE 72 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3363001402 FUEL TANK 1
1A 0605505070 FUEL TANK CAP 1
1B 0605501074 FUEL SENDER UNIT 1
1C 0605516090 GASKET 1
2 M3363001504 FUEL TANK 1
2A 0605505070 FUEL TANK CAP 1
3 0191700260 CONNECT HOSE 2
4 0605515149 HOSE BAND 4
5 M3363200404 TANK BAND 8
6 M9310500104 SUPPORTER SHEET 8
7 0016908020 HEX, HEAD BOLT 8
8 0016908055 HEX, HEAD BOLT 4
8A 0030008000 HEX, NUT 8
8B 0207308000 HEX, NUT 4
8C 0041208000 PLAIN WASHER 12
9 0191302500 VENT HOSE 1
10 0605515109 HOSE BAND 2
11 0191301200 SUCTION HOSE 1
12 0191301200 RETURN HOSE 1
13 0605515109 HOSE BAND 4

14 0602042601 RETURN PIPE .................................................. 1 ........... RE67050

15 0222101000 TANK SHEET 6

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 73

ENCLOSURE #1 ASSY.

DCA-125USJ — ENCLOSURE #1 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 74 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3413001812 BASE 1
2 M3363300303 ENVIRONMENTAL TANK 1
3 0016910030 HEX, HEAD BOLT 12
4 0603306797 PLUG 1

5 M3423001202 FRONT FRAME ................................................. 1 ........... S/N 8500001 TO 8500040

5 M3423001602 FRONT FRAME ................................................. 1 ........... S/N 8500041~

5A M3493107813 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001 TO 8500035

5A M3493107823 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036 TO 8400040

5A M3493111303 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~

6 M3423001302 FRONT FRAME ................................................. 1 ........... S/N 8500001 TO 8500040

6 M3423001702 FRONT FRAME ................................................. 1 ........... S/N 8500041~

6A M3493107813 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001 TO 8500035

6A M3493107823 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036 TO 8500040

6A M3493111303 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~

7 0601851739 GROMMET ........................................................ 1 ........... S/N 8500036 TO 8500040

8 0601850100 GROMMET ........................................................ 1 ...........

9 0016908020 HEX, HEAD BOLT 26
10 0016910025 HEX, HEAD BOLT 6

11 M3131400203 HOSE COVER ................................................... 1 ........... S/N 8500001 TO 8500040

11A M3131400103 HOSE COVER ................................................... 1 ........... S/N 8500041~

11B M3131400004 HOSE COVER ................................................... 1 ........... S/N 8500041~

12 0016908020 HEX, HEAD BOLT ............................................. 4 ........... S/N 8500001 TO 8500040

12 0016906020 HEX, HEAD BOLT ........................................... 13 ........... S/N 8500041~

13 M3423500104 BRACKET 1
14 0016906016 HEX, HEAD BOLT 6
15 M3423200704 DUCT COVER 2
16 0016906020 HEX, HEAD BOLT 14
17 M3423200804 DUCT COVER 1
18 0016906016 HEX, HEAD BOLT 6
19 M3310300104 FAN SHROUD 1
20 M3310300004 FAN SHROUD 1
21 0016906020 HEX, HEAD BOLT 14

22 M3423201003 COVER, FRONT FRAME .................................. 1 ........... S/N 8500001 TO 8500035

22 M3423201203 COVER, FRONT FRAME .................................. 1 ........... S/N 8500036~

22A M3493107904 ACOUSTIC SHEET 1

23 0016908020 HEX, HEAD BOLT ........................................... 26 ........... S/N 8500001 TO 8500040

23 0019208020 HEX, HEAD BOLT ........................................... 26 ........... S/N 8500041~

24 M3433000803 CENTER FRAME .............................................. 1 ........... S/N 8500001 TO 8500035

24 M3433000813 CENTER FRAME .............................................. 1 ........... S/N 8500036~

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 75

ENCLOSURE #1 ASSY.

DCA-125USJ — ENCLOSURE #1 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 76 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

24A M3493200614 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001 TO 8500040

24A M3493201204 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~

25 0010114040 HEX, HEAD BOLT 4
25A 0030014000 HEX, NUT 4
25B 0040014000 SPRING WASHER 4
25C 0041214000 PLAIN WASHER 8
26 0010120050 HEX, HEAD BOLT 4
26A 0030020000 HEX, NUT 4
26B 0040020000 SPRING WASHER 4
26C 0041220000 PLAIN WASHER 8
27 M3463100802 ROOF PANEL 1
27A M3493503914 ACOUSTIC SHEET 1
28 M3463200502 ROOF PANEL 1
28A M3493504003 ACOUSTIC SHEET 1
29 M3463200704 BACK PLATE 1
30 0016906016 HEX, HEAD BOLT 6
31 M3463200803 DUCT 1
31A M3493504104 ACOUSTIC SHEET 1
32 0016908020 HEX, HEAD BOLT 8
33 M3463400003 DUCT COVER 1
34 0016908020 HEX, HEAD BOLT 6
35 M3423200604 OVER COVER, FRONT FRAME 1
35A M3493108004 ACOUSTIC SHEET 1

36 0016908020 HEX, HEAD BOLT ........................................... 49 ........... S/N 8500001 TO 8500040

36 0019208020 HEX, HEAD BOLT ........................................... 49 ........... S/N 8500041~

37 0016910025 HEX, HEAD BOLT ............................................. 8 ........... S/N 8500001 TO 8500040

37 0019210025 HEX, HEAD BOLT ............................................. 8 ........... S/N 8500041~

38 M3310600004 COVER, RADIATOR CAP 1
39 0016908020 HEX, HEAD BOLT 4
40 0016908020 HEX, HEAD BOLT 6
41 M3483100004 COVER, EXHAUST PIPE 1

42 0016908020 HEX, HEAD BOLT ............................................. 2 ........... S/N 8500001 TO 8500040

43 0016908020 HEX, HEAD BOLT ............................................. 1 ........... S/N 8500041~

43A 0040508000 TOOTHED WASHER 1

44 0016906016 HEX, HEAD BOLT ............................................. 2 ........... S/N 8500001 TO 8500035

45 0605503062 FUEL LEAK DETECTION SWITCH .................. 1 ........... S/N 840003~

46 M1414800104 BRACKET ......................................................... 1 ........... S/N 840003~

47 0017108020 HEX HEAD BOLT .............................................. 2 ........... S/N 840003~

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 77

ENCLOSURE #2 ASSY.

DCA-125USJ — ENCLOSURE #2 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 78 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3443000802 REAR FRAME ................................................... 1 ........... S/N 8500001 TO 8500035

1 M3443000812 REAR FRAME ................................................... 1 ........... S/N 8500036~

1A M3493303203 ACOUSTIC SHEET 1

2 M3443000904 DUCT ................................................................. 2 ........... S/N 8500001 TO 8500035

2 M3443000914 DUCT ................................................................. 2 ........... S/N 8500036~

2A M3493303304 ACOUSTIC SHEET 2
3 0016908020 HEX, HEAD BOLT 26
4 0016910025 HEX, HEAD BOLT 4
5 M3443301003 COVER, REAR FRAME 1
5A M3493303404 ACOUSTIC SHEET 1
6 0016908020 HEX, HEAD BOLT 13
7 M3443200503 DOOR, REAR FRAME 1
8 M3443600304 WINDOW PLATE 1
9 0207306000 HEX, NUT 8
9A 0041206000 PLAIN WASHER 8
10 M9113000002 DOOR HANDLE ASSY. 1
11 0021806016 MACHINE SCREW 4
11A 0030006000 HEX, NUT 4
12 M9110100204 HINGE 2
13 M9116100004 WASHER 2
14 0016908020 HEX, HEAD BOLT 3

15 M3453200802 SPLASHER PANEL ........................................... 1 ........... S/N 8500001 TO 8500035

15 M3453200812 SPLASHER PANEL ........................................... 1 ........... S/N 8500036~

15A M3493417004 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001 TO 8500035

15A M3493417014 ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036~

16 0016908065 HEX, HEAD BOLT ............................................. 4 ........... S/N 8500001 TO 8500040

17 0016910025 HEX, HEAD BOLT ............................................. 2 ........... S/N 8500041~

18 M3453002503 SIDE DOOR 1
18A M3493416804 ACOUSTIC SHEET 1
19 M3453002603 SIDE DOOR 1
19A M3493416904 ACOUSTIC SHEET 1
20 M3453002703 SIDE DOOR 1
20A M3493417204 ACOUSTIC SHEET 1
21 M3453002803 SIDE DOOR 1
21A M3493417104 ACOUSTIC SHEET 1
22 M9113000002 DOOR HANDLE ASSY. 4
22A C9312500004 SEAL RUBBER 4
23 0021806016 MACHINE SCREW 16
23A 0030006000 HEX, NUT 16
24 M9110100804 HINGE 6
25 M9110100904 HINGE 5
26 M9116100004 WASHER 11

27 0016908020 HEX, HEAD BOLT ........................................... 26 ........... S/N 8500001 TO 8500040

27 0019208020 HEX, HEAD BOLT ........................................... 26 ........... S/N 8500041~

28 0601850097 STOPPER 8
29 0027208025 MACHINE SCREW 8
30 M9310000004 CAP 13

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 79

1

RUBBER SEALS ASSY.

DCA-125USJ — RUBBER SEALS ASSY.

PAGE 80 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229200870 RUBBER SEAL 1
2 0229201130 RUBBER SEAL 1
3 0229201240 RUBBER SEAL 3
4 0228900660 RUBBER SEAL 2
5 0229201070 RUBBER SEAL 1
6 0229200125 RUBBER SEAL 4
7 0228901165 RUBBER SEAL 3
8 0228900925 RUBBER SEAL 4
9 0228901105 RUBBER SEAL 3
10 0228900565 RUBBER SEAL 1
11 0228900945 RUBBER SEAL 4
12 0228800505 RUBBER SEAL 1
13 0229201200 RUBBER SEAL 1
14 0228800635 RUBBER SEAL 1
15 0228800970 RUBBER SEAL 2
16 0228800595 RUBBER SEAL 1
17 0228100640 RUBBER SEAL 2
18 0228100370 RUBBER SEAL 2

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 81

NAMEPLATE AND DECALS ASSY.

DCA-125USJ — NAMEPLATE AND DECALS ASSY.

PAGE 82 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

DCA-125USJ — NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1550000204 DECAL, NOTE ................................................... 1 ........... M15000020

2 M1550000703 DECAL, AUXILARY OUTPUT ............................ 1 ........... M15000070

3 M3550000004 DECAL, NOTE ................................................... 1 ........... M35000000

4 M3550001603 DECAL, GENERATOR CONTROL ..................... 1 ........... M35000160

5 M3550001703 DECAL, ENGINE OPERATING, M35000170 ..... 1 ........... S/N 8500001 TO 8500040

5 M3550002003 DECAL, ENGINE OPERATING, M35000200 ..... 1 ........... S/N 8500041~

6 M3550001803 DECAL, OPERATING PROCEDURES .............. 1 ........... M35000180A

7 M9500000004 DECAL, OIL DRAIN PLUG ................................ 1 ........... M90000000

8 M9500100004 DECAL, WATER ................................................. 1 ........... M90010000

9 M9500300004 DECAL, NEGATIVE ........................................... 1 ........... M90030000

10 M9500300104 DECAL, POSITIVE ........................................... 1 ........... M90030010

11 M9500500004 DECAL, DIESEL FUEL ..................................... 1 ........... M90050000

12 M9503000004 DECAL, WARNING MOVING PARTS ................ 2 ........... M90300000

13 M9503000103 DECAL, WATER OIL CHECK ............................ 1 ........... M90300010

14 M9503100004 DECAL, WARNING HOT COOLANT .................. 1 ........... M90310000

15 M9503200004 DECAL, WARNING ENGINE EXHAUST ........... 1 ........... M90320000

16 M9510000004 DECAL, FLUID DRAIN ...................................... 1 ........... M91000000

17 M9510100004 DECAL, CAUTION HOT PARTS ........................ 1 ........... M91010000

18 M9510100403 DECAL, CAUTION ............................................. 1 ........... M91010040

19 M9520000004 DECAL, GROUND ............................................. 1 ........... M92000000

20 M9520000104 DECAL, AMMETER CHANGE-OVER SW. ........ 1 ........... M92000010

21 M9520000204 DECAL, VOLTMETER CHANGE-OVER SW. ..... 1 ........... M92000020

22 M9520000504 DECAL, START CONTACT ................................ 1 ........... M92000050

23 M9520100004 DECAL, WARNING ELECTRIC HAZARD .......... 2 ........... M92010000

24 M9520100204 DECAL, CAUTION ............................................. 1 ........... M92010020A

25 M9520100304 DECAL, SAFETY INSTRUCTIONS ................... 1 ........... M92010030

26 M9520100404 DECAL, DANGER HIGH VOLTAGE ................... 1 ........... M92010040

27 M9520100503 DECAL, WARNING ............................................ 1 ........... M92010050

28 M9520100603 DECAL, CAUTION ............................................. 2 ........... M92010060

29 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE .. 1 ........... M92020000

30 M9520200104 DECAL, OVER CURRENT RELAY .................... 1 ........... M92020010

31 M9512200004 DECAL, MQ ....................................................... 1 ........... M91220000

32 M9510200304 DECAL, MQ POWER 3
33 M3560102004 STRIPE 2
34 M3560102103 STRIPE, WHISPERWATT 2
35 M3560102204 STRIPE 2
36 M3560102303 STRIPE, 125 1
37 M3560102403 STRIPE, 125 1
38 M3560102504 STRIPE 2

39 0600500092 PLATE, MQ POWER ......................................... 1 ........... S/N 8400031~

39A 0021106016 MACHINE SCREW ............................................ 4 ........... S/N 8400031~

40 M9510100304 DECAL, ENVIRONMENTAL WARNIN6 .............. 1 ........... S/N 8400031~

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 83

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit
will be allowed, subject to the following provi­sions:

1. A Returned Material Authorization must
be approved by Multiquip prior to ship­ment.

2. To obtain a Retur n Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers, quanti­ties, and descriptions of the items to be
returned.

a. The parts numbers and descriptions

must match the current parts price
list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the
items were originally purchased.

e. The list must include the name and

phone number of the person request­ing the RMA.

3. A copy of the Return Material Authoriza­tion must accompany the return shipment.

4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior
notice. Price changes are effective on a spe­cific date and all orders received on or after
that date will be billed at the revised price.

Rebates for price declines and added charges
condition, in the original Multiquip pack­age (if any), and with Multiquip part
numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being
replaced by another item, it is
obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.
e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.

dealer net price at time of the original
purchase, less a 15% restocking charge.

which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.

purchases only.

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade acces-

sories nor as to any engine not manufactured

by Multiquip. Such warranties made in connec-

tion with the sale of new, complete units are

made exclusively by a statement of warranty

packaged with such units, and Multiquip nei-

ther assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 84 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04)

NOTE PAGE

1

DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #0 (06/24/04) — PAGE 85

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

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: [e-mail]
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

Your Local Dealer is:

Manufactured for Multiquip Inc.

by

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-mail: [e-mail]
Internet: www.mqpower.com