Page 1
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA125SSIU
50HZ GENERATOR
(ISUZU 4HK1X DIESEL ENGINE)
PARTS LIST NO. M3870301204
Revision #0 (12/22/08)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Page 2
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 3
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffi c Safety Administration (NHTSA) in addition to notifying Multiquip at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
fi nds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at
1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or
write to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 3
Page 4
TABLE OF CONTENTS
DCA125SSIU Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information .............................................. 6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................ 14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ........................................ 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-24
Load Application .................................................... 25
Generator Outputs ............................................ 26-27
Gauge Reading ..................................................... 27
Output Terminal Panel Connections ................. 28-29
Inspection/Setup ............................................... 30-33
Generator Start-Up Procedure (Manual) .......... 34-35
Generator Start-Up ProceduRe (Auto Mode) ........ 36
Generator Shut-Down Procedures ........................ 37
Maintenance ..................................................... 38-41
Trailer Maintenance .......................................... 42-44
Trailer Wiring Diagram ........................................... 45
Generator Wiring Diagram ..................................... 46
Engine Wiring Diagram .......................................... 47
Controller Wiring Diagram ..................................... 48
Troubleshooting (Generator) .................................. 49
Troubleshooting (Engine Controller) ...................... 50
Troubleshooting (Diagnostic Lamp) ....................... 51
Explanation Of Code In Remarks Column............. 52
Suggested Spare Parts ......................................... 53
Component Drawings
Generator Assembly ......................................... 54-55
Control Box Assembly ...................................... 56-61
Engine And Radiator Assembly ........................ 62-65
Output Terminal AsseMbly ................................ 66-67
Battery Assembly.............................................. 68-69
Muffl er Assembly .............................................. 70-71
Fuel Tank Assembly ......................................... 72-73
Enclosure Assembly ......................................... 74-79
Rubber Seals Assembly ................................... 80-81
Nameplate And Decals Assembly .................... 82-85
Terms And Conditions Of Sale — Parts ................ 86
PAGE 4 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 5
Best Deal!
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
■
Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Use the
on
complete part numbers.*
Fax
on
Standard orders
complete part numbers.*
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
internet
and qualify for a 5% Discount
Standard orders
your order in and qualify for a 2% Discount
Effective:
January 1
st
, 2006
for all orders which include
Note: Discounts Are Subject To Change
for all orders which include
Note: Discounts Are Subject To Change
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒❒
❒
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
❒❒
All orders are treated as
and will ship the same day if received prior
to 3PM PST.
Domestic (US) Dealers Call:
1-800-427-1244
International Customers
their local Multiquip Representatives for
Parts Ordering information.
❒❒
❒
Specify Preferred Method of Shipment:
❒❒
✓
UPS/Fed Ex
■
Priority One
■
Ground
■ Next Day
■
Second/Third Day
Standard Orders
should contact
✓ DHL
✓
Tr u ck
www.mqpower.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 5
Page 6
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. 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.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 7
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
GENERATOR SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air
is restricted. If the air fl ow
is restricted it will cause
injury to people and property
and serious damage to the
equipment or engine.
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest phone or
keep a phone on the job site. Also, know the phone
numbers of the nearest ambulance, doctor and fi re
department. This information will be invaluable in the
case of an emergency.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 7
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel.
Page 8
SAFETY INFORMATION
ENGINE SAFETY
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water will gush out
of the radiator and severely scald any persons in the
general area of the generator.
DO NOT remove the coolant drain plug
while the engine is hot. Hot coolant will
gush out of the coolant tank and severely
scald any persons in the general area of
the generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
PAGE 8 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
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SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety towing
regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order 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 mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
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.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 9
Page 10
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe injury or even
death through physical contact with live circuits. Turn
generator and all circuit breakers OFF before performing
maintenance on the generator or making contact with
output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility
exists of electrical shock, electrocution
or death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be performed by a
licensed electrician in accordance with all applicable
laws and electrical codes. Failure to do so could result
in electrical shock or burn, causing serious injury or
even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 11
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel
and fuel fi lters.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 11
Page 12
SPECIFICATIONS
Generator Specifi cationsTable 1.
Model
Type
Armature Connection Star with Neutral Zigzag
Phase
Standby Output
Prime Output
Power Factor
Voltage
Frequency
Speed
Aux. AC Power
Aux. Voltage/Output
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
110 kVA (88 kW) 63 kW
100 kVA (80 KW) 57 KW
200 or 400V 100 or 200V
Engine Specifi cationsTable 2.
4 cycle, water-cooled, direct injection, turbo-charged
Revolving fi eld, self ventilated,
open protected type synchronous generator
3 Single
0.8 1.0
4.53 in. x 4.92 in. (115 mm x 125 mm)
5.8 gal. (22.0 L)/hr at full loa
DCA-125SSIU
50 Hz
1500 rpm
Single Phase, 50 Hz
4.8 Kw (2.4 kW x 2)
ISUZU 4HK1X
with charged air-cooled
4 cylinders
317 cu. in. (5,193 cc)
Electric
5.30 gal. (20.2 liters)
5.99 gal. (22.7 liters)
#2 Diesel Fuel
63 gal. (240 liters)
12V-128 Ah x 1
PAGE 12 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 13
DIMENSIONS
DimensionsFigure 1.
DimensionsTable 3.
Reference
Letter
A 34.76 in. (883 mm.) F 120 in. (3,050 mm.)
B 34.76 in. (883 mm.) G 55.11 in. (1,400 mm.)
C 37.20 in. (945 mm.) H 43.30 in. (1,100 mm.)
D 38.18 in. (970 mm.)
E 37.20 in. (945 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 13
Page 14
INSTALLATION
Typical Generator Grounding ApplicationFigure 2.
PAGE 14 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 15
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.
CAUTION
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
specifi es 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:
Use one of the following wire types to connect the 1.
generator to earth ground.
Copper - 10 AWG (5.3 mm2) or larger.a.
Aluminum - 8 AWG (8.4 mm2) or larger.b.
When grounding the generator (Figure 2) connect the 2.
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.
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 fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor 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.
NEC article 250-52(c) specifi es that the earth ground rod 3.
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 15
Page 16
GENERAL INFORMATION
GENERATOR
The MQ Power Model DCA125SSIU generator (Figure 3) is
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:
Tachometer
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Engine Speed Switch
Auto START/STOP Engine Controller (ECU)
Panel Light/Panel Light Switch
Pre-Heat Lamp
Warning Lamp
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 300 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Automatic Voltage Regulator•
Current Transformer•
Over-Current Relay•
Starter Relay•
Engine Controller (Computer Controlled)•
Voltage Selector Switch•
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 100/200V output receptacles (CS-6369), 50A
Three auxiliary circuit breakers, 50A
Two 100V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
OPEN DELTA EXCITATION SYSTEM
The DCA125SSIU generator is equipped with the state of
the art “Open-Delta” excitation system. The open delta
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 rectifi ed 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 confi guration 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 “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
The DCA125SSIU is powered by a 4 cylinder, water cooled,
direct injection, turbocharged air-to-air intercooled ISUZU
4HK1X diesel engine. This engine is designed to meet every
performance requirement for the generator. Reference
Table 2 for engine specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations 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 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 17
MAJOR COMPONENTS
Generator Major ComponentsTable 4.
ITEM NO. DESCRIPTION
1 Muffl er Assembly
2 Air Filter Assembly
3 Voltage Selector Switch
4 Output Terminal Panel Assembly
5 Generator Assembly
6 Output Receptacles Assembly
7 Engine Assembly
8 Battery Assembly
9 Fuel Tank Assembly
10 Main Circuit Breaker Assembly
11
Generator/Engine Operating Panel
Assembly
Major ComponentsFigure 3.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 17
Page 18
GENERATOR CONTROL PANEL
5
2
INCREASE
1
DECREASE
3
V
U
W
OFF
V-W
W-U
U-V
OFF
4
HZ
A
V
7
Generator Control PanelFigure 4.
The defi nitions below describe the controls and functions
of the DCA125SSIU Generator Control Panel (Figure 4).
Main Circuit Breaker1. —This three-pole, 300A main
breaker is provided to protect the the U,V, and W Output
Terminal Lugs from overload.
Voltage Regulator Control 2. — Allows ±15% manual
adjustment of the generator’s output voltage.
6
AUTO
MANUAL
OFF/RESET
LOW OILPRESSURE
HIGH COOLANTTEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
Over-Current Relay
Ammeter Change-Over Switch 3. — This switch allows
the AC ammeter to indicate the current fl owing 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.
Voltmeter Change-Over Switch 4. — 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.
Frequency Meter 5. — Indicates the output frequency
in hertz (Hz). Normally 50 Hz.
AC Ammeter 6. — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
AC Voltmeter 7. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
Automatic Voltage Regulator (AVR)
Starter Relay
Current Transformer
Voltage Selector Switch
Main Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
fl owing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 300 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 18 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 19
NOTES
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 19
Page 20
ENGINE OPERATING PANEL
OFF
W
U
V
OFF
W-U
V-W
U-V
DECREASE
INCREASE
6
HZ
A
V
5
1
2
3
4
7
LOW OIL PRESSURE
HIGH COOLANT TEMPERATURE
OVERCRANK
OVERSPEED
ENGINE RUNNING
MOOOOO-20001Q
11
AUTO
OFF/RESET
10
8
9
MANUAL
Engine Operating PanelFigure 5.
PAGE 20 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 21
ENGINE OPERATING PANEL
The defi nitions below describe the controls and functions of
the DCA-125SSIU Engine Operating Panel (Figure 5).
Tachometer 1. — Indicates engine speed in RPM’s for 50
Hz operation. This meter should indicate 1500 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
Fuel Gauge 2. — Indicates amount of diesel fuel
available.
Charging Ammeter Gauge 3. — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
Water Temperature Gauge 4. — During normal operation
this gauge be should read between 167°~203°F (75°
~95°C
Oil Pressure Gauge 5. — During normal operation this
gauge should read between 42 ~71 psi. (290~490 kPa).
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.
Panel Light 6. — 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.
Panel Light Switch 7. — When activated will turn on
control panel light.
Pre-Heat Lamp 8. — As the engine cranks, this lamp
will illuminate to indicate automatic preheating of
the engine glow plugs. When the lamp turns off, this
indicates that the preheat cycle is complte and the
engine will start automatically.
Warning Lamp 9. — Indicates that a failure has occured
in the engine control system.
Engine Speed Switch 10. — This switch controls the
speed
Auto START/STOP Engine Controller (ECU) 11. — 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. During cranking
cycle, the ECU will attempt to
crank the engine for 10 seconds
before disengaging.
If the engine does not engage (start) by the third
attempt, the engine will be shutdown by the engine
controller’s Over Crank Protection mode. If the engine
engages at a speed (RPM's) that is not safe, the
controller will shutdown the engine by initializing the
Over Speed Protection mode.
Also the engine controller will shut down the 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.
MPEC Control Switch A. — This switch controls the
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 an automatic transfer switch
(isolation), place the switch in the AUTO position. In this
position, should an outage occur, the automatic transfer
switch (ATS) will start the generator automatically
via the generator’s auto-start contacts connected to
the ATS’s start contacts. Please refer to your ATS
installation manual for further instructions for the
correct installation of the auto-start contacts of the
generator to the ATS.
Low Oil Pressure B. — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
High Coolant Temperature C. — Indicates the engine
temperature has exceeded 230°F (110°C). The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
Overcrank Shutdown D. — Indicates the unit has
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 major fault.
Overspeed Shutdown E. — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
Engine Running F. — Indicates that engine is running
at a safe operating speed.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 21
Page 22
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is
located 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.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three (3) 100/200V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 100V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
Output Terminal PanelFigure 6.
PAGE 22 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 23
OUTPUT TERMINAL PANEL FAMILIARIZATION
100 VAC GFCI Receptacles
There are two 100 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch 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 U, V, and W output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 7) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Each auxiliary 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 voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Voltage Regulator Control KnobFigure 9.
G.F.C.I. ReceptacleFigure 7.
Twist Lock Dual Voltage 100/200 VAC Receptacles
There are three 100/200V, 50 amp auxiliary twist-lock (CS-
6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
100/200V Twist-Lock Auxiliary Figure 8.
Receptacles
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 23
Page 24
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 10).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3-pole,
300A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Over Current Relay
An over current relay (Figure 11) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
Over Current RelayFigure 11.
Connecting LoadsFigure 10.
PAGE 24 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 25
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
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 infl uenced by the effi ciency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Power Factor By LoadTable 5.
Type of Load Power Factor
Single-phase induction motors 0.4-0.75
THREE PHASE LOAD
When calculating the power requirements for 3-phase
power use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can
burn out the appliance or tool and overheat the cable. See
Table 6.
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.4-0.9
Electronic devices, communication
equipment
1.0
Common power tools 0.8
Cable Selection (60 Hz, Single Phase Operation)Table 6.
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
When connecting a fl uorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
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
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 25
Page 26
GENERATOR OUTPUTS
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 12). To obtain some of
the voltages as listed in Table 7 (see below) will require a
fi ne adjustment using the voltage regulator (VR) control
knob located on the control panel.
Voltage Selector Switch
The voltage selector switch (Figure 12) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
Maximum Amps
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Generator Maximum AmpsTable 8.
Rated Voltage Maximum Amps
Single Phase 100 Volt 266 amps (4 wire)
Single Phase 200 Volt 133 amps (4 wire)
Three Phase 200 Volt 288 amps
Three Phase 400 Volt 144 amps
Voltage Change-Over BoardFigure 12.
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the
engine is running. To lock the voltage selector switch, press
and hold the red button located at the bottom of the switch.
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Voltages AvailableTable 7.
Three Phase
(Switchable)
Single Phase
(Switchable)
200V 220V 416V 440V
115V 127V 240V 254V
PAGE 26 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 27
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE OUTPUT TERMINAL GAUGE
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 13) to the position which produces
the required voltage (For example, for 3Ø 200V, choose
the center 3Ø 240/139V position on the voltage selector
switch.)
Reading Amperage
To determine the amperage at a terminal lug, set the AC
Ammeter Change-Over Switch to the appropriate setting
(Figure 16) to activate the AC Ammeter Gauge (Figure 17)
and read the available amperage at the terminal lug.
For example, to measure the amperage at the U terminal
lug, set the AC Ammeter Change-Over Switch to U and
read the AC Ammeter Gauge.
AC Ammeter Figure 16.
Change-Over Switch
NOTICE
(Amp Reading on U Lug)
AC AmmeterFigure 17.
Voltage Selector SwitchFigure 13.
240/139V 3
Ø Positio
NOTICE
For 3Ø 200V/1Ø,115V, place the Voltage Selector
Switch in the 3 Phase 340/139 position.
Reading Voltage
To determine the voltage between two terminal lugs, set
the AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 14) to activate the AC Voltmeter Gauge
(Figure 15) and read the available voltage between the
two lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the AC Voltmeter Gauge.
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
AC Voltmeter Figure 14.
Change-Over Switch
AC Voltmeter Figure 15.
Gauge
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 27
Page 28
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control
Knob.
Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.
3Ø-220/127 UVWO Terminal Output Voltages
Place the voltage selector switch in the 3Ø 240/139 1.
position as shown in Figure 18..
Turn the voltage regulator knob (Figure 20) clockwise 3.
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required.
Voltage Regulator KnobFigure 20.
3Ø-200V/1Ø-115V UVWO Terminal Output Voltages
Place the voltage selector switch in the 3Ø 240/139 1.
position as shown in Figure 21.
Voltage Selector SwitchFigure 18.
3Ø-240/139V Position
Connect the load wires to the UVWO terminals as 2.
shown in Figure 19.
UVWO Terminal Lugs Figure 19.
3Ø-220/127V Connections
Voltage Selector SwitchFigure 21.
3Ø-240/139V Position
Connect the load wires to the UVWO terminals as 2.
shown in Figure 22.
UVWO Terminal LugsFigure 22.
3Ø-200/1Ø-115V Connections Connections
NOTICE
To achieve a 3Ø 200V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 200V..
PAGE 28 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 29
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-440/254V UVWO Terminal Output Voltages
Place the voltage selector switch in the 3Ø 480/277 1.
position as shown in Figure 23.
Voltage Selector SwitchFigure 23.
3Ø-480/277V Position
Connect the load wires to the UVWO terminals as 2.
shown in Figure 24.
1Ø-200/100V UVWO Terminal Output Voltages
Place the voltage selector switch in the 1Ø 240/120 1.
position as shown in Figure 25.
Voltage Selector SwitchFigure 25.
1Ø-240/120V Position
Connect the load wires to the UVWO terminals as 2.
shown in Figure 26.
UVWO Terminal Lugs Figure 24.
3Ø-440/254V Connections
Turn the voltage regulator knob (Figure 20) clockwise 3.
to increase voltage output, turn counterclockwise
to decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required.
1Ø-200/100V Connections
Turn the voltage regulator knob (Figure 20) clockwise 3.
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required.
UVWO Terminal Lugs Figure 26.
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fi re.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 29
Page 30
INSPECTION/SETUP
CIRCUIT BREAKERS
To protect the generator from an overload, a 3-pole, 300
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload. Three 50 amp
load circuit 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
fi ller hole, but DO NOT overfi ll. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 27) on the dipstick. See Table 9 for
proper selection of engine oil.
FUEL CHECK
DANGER
Fuel spillage on a hot engine can cause
a fi re or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refi lling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understand this section should refi ll the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 28). ALWAYS fi ll the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fi ll the fuel
tanks beyond their capacities.
Engine Oil DipstickFigure 27.
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 refi ll with the specifi ed amount of oil as
outlined in the ISUZU Engine Owner’s Manual. Oil should
be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classifi cation CC/SC
API Service Classifi cation CC/SD
API Service Classifi cation CC/SE
API Service Classifi cation CC/SF
Recommended Motor OilTable 9.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after fi lling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Internal Fuel Tank SystemFigure 28.
PAGE 30 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 31
INSPECTION/SETUP
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
Level Tanks1. — 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 29).
CAUTION
ALWAYS place trailer on fi rm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Open cabinet doors on the “right side” of the generator 2.
(from generator control panel position). Remove fuel
cap and fi ll tank (Figure 30).
Fueling the GeneratorFigure 30.
NEVER overfi ll fuel tank3. — It is important to read the
fuel gauge when fi lling trailer fuel tank. DO NOT wait
for fuel to rise in fi ller neck (Figure 31).
Only Fill on Level GroundFigure 29.
NOTICE
ONLY use #2 diesel fuel when refueling.
Full Fuel TankFigure 31.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 32).
Fuel ExpansionFigure 32.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 31
Page 32
INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
ISUZU recommends ISUZU antifreeze/summer coolant for
use in their engines, which can be purchased in concentrate
(and mixed with 50% demineralized water) or pre-diluted. See
the ISUZU Engine Owner’s Manual for further details.
WARNING
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe 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 10 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.
CLEANING THE RADIATOR
The engine may overheat if the radiator fi ns become
overloaded with dust or debris. Periodically clean the
radiator fi ns with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
AIR CLEANER
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the ISUZU Engine Owner’s Manual.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insuffi cient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
ISUZU Engine Owner’s Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 33) when depressed with the thumb as shown
below.
Coolant CapacityTable 10.
Engine and Radiator 5.3 gal (20.2 liters)
Reserve Tank 2 quarts (1.9 liters)
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 11) has been added.
Anti-Freeze Table 11.
Operating Temperatures
Vol %
Anti-Freeze
50 -37 -34
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
Freezing Point
°C °F
Fan Belt TensionFigure 33.
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
PAGE 32 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 33
INSPECTION/SETUP
BATTERY
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fl uid level between the specifi ed
marks. Battery life will be shortened, if the fl uid 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. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery. The battery is suffi ciently
charged if the specifi c gravity of the battery fl uid is 1.28
(at 68° F). If the specifi c 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
When connecting battery do the following:
NEVER1. connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
Place a small amount of battery terminal treatment 2.
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
NOTICE
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.
CAUTION
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ALWAYS be sure the battery cables (Figure 34) 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.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Battery ConnectionsFigure 34.
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 corrosion and damage the
alternator.
WIRING
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 (fuel or oil) lines are defective replace them
immediately.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 33
Page 34
GENERATOR START-UP PROCEDURE (MANUAL)
T
BEFORE STARTING
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main, GFCI or
auxiliary circuit breakers in the ON (closed) position.
Place the 1. main, G.F.C.I., and aux. circuit breakers (Figure
35) in the OFF position prior to starting the engine.
Main, Aux. and GFCI Figure 35.
Circuit Breakers (OFF)
STARTING (MANUAL)
Place the engine speed switch (Figure 37) in the LOW 1.
(down) position.
Engine Speed Switch (Low)Figure 37.
Place the 2. MPEC control switch in the MANUAL
position to start the engine (Figure 38).
MPEC Control Switch Figure 38.
(Manual Position)
Depending on the temperature of the coolant (cold 3.
weather conditions), the pre-heat lamp (Figure 39) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
Make sure the 2. voltage change-over board has been
confi gured for the desired output voltage.
Connect the load to the 3. receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Tighten terminal nuts securely to prevent load wires 4.
from slipping out.
Close all engine enclosure doors (Figure 36).5.
CORRECT
Engine Enclosure DoorsFigure 36.
INCORREC
Pre-Heat LampFigure 39.
Once the engine starts, let the engine run for 1-2 4.
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 40) in the HIGH (up)
position.
Engine Speed Switch (High)Figure 40.
Verify that the 5. engine running
status LED on the MPEC unit
(Figure 41) is ON (lit) after the
engine has been started.
Engine Running LED (ON)Figure 41.
PAGE 34 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 35
GENERATOR START-UP PROCEDURE (MANUAL)
The generator’s frequency meter (Figure 42) should be 6.
displaying the 50 cycle output frequency in HERTZ.
Frequency MeterFigure 42.
The generator’s AC-voltmeter (Figure 43) will display 7.
the generator’s output in VOLTS. If the voltage is not
within the specified tolerance, use the voltage
adjustment control knob (Figure 44) to increase or
decrease the desired voltage.
VoltmeterFigure 43.
The 10. coolant temperature gauge (Figure 47) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Coolant Temperature GaugeFigure 47.
The11. tachometer gauge (Figure 48) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1500 RPM’s.
Engine Tachometer GaugeFigure 48.
Voltage Adjust Control KnobFigure 44.
The ammeter (Figure 45) will indicate 8. 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.
Ammeter (No Load)Figure 45.
The engine oil pressure gauge (Figure 46) will indicate 9.
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
Place the 12. main, GFCI, and aux. circuit breakers in the
ON position (Figure 49).
Main, Aux. and GFCI Figure 49.
Circuit Breakers (ON)
Observe the generator’s ammeter (Figure 50) and 13.
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.
Ammeter (Load)Figure 50.
The generator will run until manually stopped or an 14.
Oil Pressure GaugeFigure 46.
abnormal condition occurs.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 35
Page 36
GENERATOR START-UP PROCEDURE (AUTO MODE)
STARTING (AUTO MODE)
DANGER
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to
the building’s electrical system may occur without this
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.
NOTICE
When the generator is set in the AUTO mode, the
generator will automatically start in the event of
commercial power falling below a prescribed level
by means of a contact closure that is generated
automatically by a transfer switch.
When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
Perform steps 1 through 5 in the Before Starting section 1.
as outlined in the Manual Starting Procedure.
Place the 2. engine speed switch (Figure 51) in the
HIGH position
Engine Speed Switch (High)Figure 51.
Place the 3. MPEC Control Switch (Figure 52) in the
AUTO position.
MPEC Control Switch (AUTO)Figure 52.
Continue operating the generator as outlined in the 4.
Manual Start-up procedure (start at step 5).
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.
CAUTION
The engine speed switch must be set to the “High”
position when running in the auto-start mode. Failing
to set the switch in the proper position can result in
damage to your generator when it turns on.
NOTICE
When the MPEC control switch is placed in the AUTO
position, the engine glow plugs will be warmed and the
engine will start automatically.
PAGE 36 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 37
GENERATOR SHUT-DOWN PROCEDURES
WARNING
NEVER stop the engine suddenly except in an
emergency.
NORMAL SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure:
Place both the 1. MAIN, GFCI and LOAD circuit breakers
as shown in Figure 35 to the OFF position.
Place the engine speed switch (Figure 53) in the “LOW” 2.
(down) position.
Engine Speed Switch (Low)Figure 53.
Let the engine cool by running it at low speed for 3-5 3.
minutes with no load applied.
Place the 4. MPEC Control Switch (Figure 54) to the
OFF/RESET position.
EMERGENCY SHUTDOWN PROCEDURE
Place the ECU Control Switch switch (Figure 54) to 1.
the OFF/Reset position.
To shut-down the engine in the event of an emergency, 2.
switch the MAIN, GFCI and LOAD (Figure 35) circuit
breakers to OFF position.
MPEC Control Switch (Off/Reset)Figure 54.
Verify that 5. all the status LEDs on the MPEC display
are OFF (not lit).
Remove all loads from the generator.6.
Inspect entire generator for any damage or loosening 7.
of components that may have occurred during
operation.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 37
Page 38
MAINTENANCE
Engine
Generator
2
10 Hrs
DAILY
250 Hrs 500 Hrs
X
X
X
Inspection/MaintenanceTable 12.
Check Engine Fluid Levels X
Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Parts X
Replace Engine Oil and Filter *
Clean Air Filter X
Check Fuel Filter/Water Separator Bowl X
Clean Unit, Inside and Outside X
Change Fuel Filter X
Clean Radiator and Check Coolant Protection Level*
Replace Air Filter Element *
Check all Hoses and Clamps *
Clean Inside of Fuel Tank X
Measure Insulation Resistance Over 3M ohms X
Check Rotor Rear Support Bearing X
*1 Replace engine oil and fi lter at 100 hours, fi rst time only.
*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
*3 Replace primary air fi lter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
with no sags or dips that could collect moisture and/or oil.
1
3
4
1000
Hrs
X
GENERAL INSPECTION
Prior to each use, the generator should be cleaned and
inspected for defi ciencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 12 as a general
maintenance guideline Engine Side (Refer to the Engine
Instruction Manual)
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 55)
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 (Figure 55) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
NOTICE
The air fi lter should not be changed until the indicator
reads “RED”. Dispose of old air fi lter. It may not be
cleaned or reused.
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.
PAGE 38 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Air Cleaner/IndicatorFigure 55.
Page 39
MAINTENANCE
If the engine is operating in very dusty or dry grass
conditions, a 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 frequently if these 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.
Cleaning Inside the Fuel Tank
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 56) wash out any deposits
or debris that have accumulated inside the fuel tank.
FUEL TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Fuel Tank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
Replace the fuel fi lter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel fi lter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air
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 ISUZU
Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Fuel Tank CleaningFigure 56.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 39
Page 40
MAINTENANCE
CHECK OIL LEVEL
Check the crankcase oil level prior to each use, or when the
fuel tank is fi lled. Insuffi cient 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 27.
Replacing Oil Filter
Remove the old oil fi lter.
Apply a fi lm of oil to the gasket on the new oil fi lter.
Install the new oil fi lter.
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.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
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 overfl ow
tank and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Tighten both cocks and replace the overfl ow tank.
Replace with coolant as recommended by the engine
manufacturer.
Close radiator cap tightly.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
WARNING
Allow engine to cool when fl ushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
RADIATOR CLEANING
The radiator (Figure 57) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fi ns or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fi ns and tube.
Radiator CleaningFigure 57.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refi ll if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
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 40 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 41
TRAILER MAINTENANCE
TRAILER MAINTENANCE
This section is intended to provide the user with generic
trailer service and maintenance information. The service
and maintenance guidelines referenced in this section refer
to a wide range of trailers.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
Fuel Cell 1. — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
Braking System 2. — System employed in stopping
the trailer. Typical braking systems are electric, surge,
hydraulic, hydraulic-surge and air.
GVWR 3. — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
Frame Length 4. — Measurement is from the ball hitch
to the rear bumper (refl ector).
Tire Size 8. — Indicates the diameter of the tire in
inches (10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
Tire Ply 9. — The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
Wheel Hub 10. — The wheel hub is connected to the
trailer’s axle.
Tire Rim 11. — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
Lug Nuts 12. — Used to secure the wheel to the wheel
hub. Always use a torque wrench to tighten down
the lug nuts. See Table 16 and Figure 60 for lug nut
tightening and sequence.
Axle 13. — 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.
Suspension 14. — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-fl ex, and air ride.
Frame Width 5. — Measurement is from fender to
fender
Jack Stand 6. — Trailer support device with maximum
pound requirement from the tongue of the trailer.
Coupler 7. — Type of hitch used on the trailer for
towing.
Electrical 15. — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
Application 16. — Indicates which units can be employed
on a particular trailer.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 41
Page 42
TRAILER MAINTENANCE
BRAKES
Trailer brakes should be inspected the fi rst 200 miles of
operation. This will allow the brake shoes and drums to seat
properly. After the fi rst 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Figure 58 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 8 and Table 13 as listed below:
Brake Adjustment
Place the trailer on jack stands. Make sure the jack 1.
stands are placed on secure level ground.
Check the wheel and drum for free rotation.2.
Remove the adjusting hole cover from the adjusting 3.
slot at the bottom brake backing plate.
With a screwdriver or standard adjusting tool, rotate 4.
the star wheel of the adjuster assembly to expand the
brake shoes.
Adjust the brake shoes outward until the pressure of 5.
the lining against the wheel drum makes the wheel
diffi cult to turn.
Adjust, rotate the star wheel in the opposite direction 6.
until the wheel rotates freely with slight lining drag.
Replace the adjusting hole cover and lower the trailer 7.
to the ground.
Repeat steps 1 through 7 on the remaining brakes.8.
Hydraulic Surge Brakes
Hydraulic surge brakes (Figure 58) should not require any
special attention with the exception of routine maintenance
such as shoe and lining replacement. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Hydraulic Brake ComponentsFigure 58.
Actuator
Hydraulic surge braking requires the installation of an
actuator at the tongue of the trailer. Remember the surge
or push of the trailer toward the tow vehicle automatically
synchronizes the trailer brakes with the tow vehicle brakes.
As the trailer 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 “actuator” to make sure that
it is functioning correctly. Never use an undersize actuator.
Hydraulic Brake TroubleshootingTable 13.
Symptom Possible Cause Solution
No Brakes Brake line broken or kinked? Repair or replace.
Brake lining glazed? Reburnish or replace.
Weak Brakes or Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging Brakes
Trailer overloaded? Correct weight.
Brake drums scored or grooved? Machine or replace.
Tire pressure correct? Infl ate all tires equally.
Tires unmatched on the same axle? Match tires.
Brake components loose, bent or
broken?
Brake drums out-of-round? Replace.
System lubricated? Lubricate.
Brake components correct? Replace and correct.
Brake lining thickness incorrect or
not adjusted correctly?
Enough brake fl uid or correct fl uid?
Replace components.
Install new shoes and
linings.
Replace rubber parts
fi ll with dot 4 fl uid.
PAGE 42 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 43
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.
CAUTION
ALWAYS wear safety glasses when
removing or installing force fi tted parts.
Failure to comply may result in serious
injury.
CAUTION
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/Infl ation
Suspension
The leaf suspension springs and associated components
(Figure 59) 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
as detailed in Table 15.
Major Suspension ComponentsFigure 59.
Tire infl ation 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 infl ation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 14 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Tire Wear TroubleshootingTable 14.
Wear Pattern Cause Solution
Center Wear Over infl ation.
Edge Wear Under infl ation.
Side Wear
Toe Wear Incorrect toe-in. Align wheels.
Cupping Out-of-balance.
Flat Spots
Loss of camber
or overloading.
Wheel lockup and
tire skidding.
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.
Suspension Torque RequirementsTable 15.
Item Torque (Ft.-Lbs.)
3/8" U-Bolt Min-30 Max-35
7/16" U-Bolt Min-45 Max-60
1/2" U-Bolt Min-45 Max-60
Shackle Bolt
Spring Eye Bolt
Shoulder Type
Shackle Bolt
Snug fi t only. Parts must rotate freely.
Locking nuts or cotter pins are
provided to retain nut-bolt assembly.
Min-30 Max-50
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 43
Page 44
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:
Start all wheel lug nuts by hand.1.
Torque all lug nuts in sequence (see Figure 60). 2. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defi ned
by Table 16.
After fi rst road use, retorque all lug nuts in sequence. 3.
Check all wheel lug nuts periodically.
Tire Torque RequirementsTable 16.
Wheel Size
12" 20-25 35-40 50-65
13" 20-25 35-40 50-65
14" 20-25 50-60 90-120
15" 20-25 50-60 90-120
16" 20-25 50-60 90-120
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
TRAILER MAINTENANCE
Wheel Lug Nuts Figure 60.
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
PAGE 44 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 45
TRAILER WIRING DIAGRAM
Trailer/Towing Vehicle Wiring DiagramFigure 61.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 45
Page 46
CN1
-
+
2 3
32
1
-
-
CN2
CN3
BR
GR
1
AJ C
1
1
U
CB2
CON1
X
W
Y
G
CB3
CON2
X
W
Y
G
G
CB4
CON3
X
W
Y
G
G
G
CON4
W
CON5
W
G
G
COLOR CODE
WIRE COLOR
BLACK
B
BLUE
L
BROWN
GREEN
G
GRAY
V
VIOLET
P
PINK
2
3
DKB
234
k
P1
P2
CONNECTOR ARRANGEMENT
VW
CB5
HOT
G
CB6
HOT
G
WIRE COLOR
RED
R
W
WHITE
Y
YELLOW
LB
LIGHT BLUE
LG
LIGHT GREEN
ORANGE
O
1
2
1
3
CN4
1
CN5
V2
V2
(WIRING VIEW)
CN6
432
O
1
V1
CN7
TO Eng. Wiring
Diagram
(ACC 1)
TO CN8
X2Y2
234
-
V1
TO
SW 20,24,22
TO
CN11
TO
CT2"l"
CT3
Z2
CN8
+
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CN6
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37
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13
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X1Y1Z1
CN11
213
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RST
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GENERATOR WIRING DIAGRAM
R
R
(U1)
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CN9
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LB
V2 W2
A
(U1)
W
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(W1)
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CN10
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T.C.
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TERMINAL
“0”
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4
8
18
20
24
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12
40
SW
CT2
GR
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42
38
36
26
22
30
10
14
32
34
l
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98 97
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1
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TO
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TO
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(V2)
(U2)
OC
TO CB1 "U"
TO CB1 "W"
W
4
2
6
U2
B
C
D
Ar
Fg
BRUSHLESS AC GENERATOR
1
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U2
3
W2
1
23
V1U1W1
1
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Re
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Ar
Ex
Fg
SYMBOL
CT 1,2,3
CB 1,2,3,4,5,6
CON 1,2,3,4, 5,6
Notice
1. No designation lead size : 1.25
R
W
(V1)
S
L
(W1)
T
CN12
(V1)
(V1)
V1
V1
W
CN6
S
R
T
CN6
+-
RY2
CN5
+-
RY1
CN11
CN12
(W2) (W2)
(U2)
R
(V2)
(W2) (V2)
CN3
CN1
VW
U
A
B
AVR
C
D
JK
(J)
(K)
Ar
Fg
ExAr
ExFg
Re
AVR
VR
AS
A~
VS
V
F
OC
SW
MAIN GENERATOR ARMATURE WINDING
MAIN GENERATOR FIELD WINDING
EXCITER ARMATURE WINDING
EXCITER FIELD WINDING
RECTIFIER
AUTOMATIC VOLTAGE REGULATOR
VOLTAGE REGULATOR (RHEOSTAT)
CURRENT TRANSFORMER
CHANGE-OVER SWITCH,AMMETER
AC.AMMETER
CHANGE-OVER SWITCH,VOLTMETER
AC.VOLTMETER
FREQUENCY METER
OVER CURRENT RELAY
CIRCUIT BREAKER
RECEPTACLE
SELECTOR SWITCH
:
Y
Y
~
VS
RY2
G
Y
~
AS
G
G
(U2)(U2)
CN5
W
1
2
CN4
1
3
P
1
P2
k
CN2
W
DESIGNATION
V
A
F
RY1
V2
V2
W
W
CN11
CN12
1
GR
GR
Y
W
2
GR
Y
3
VR
Generator Wiring DiagramFigure 62.
PAGE 46 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 47
ENGINE WIRING DIAGRAM
Engine Wiring DiagramFigure 63.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 47
Page 48
CONTROLLER WIRING DIAGRAM
Controller Wiring DiagramFigure 64.
PAGE 48 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 49
TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business offi ce or service plant.
Generator TroubleshootingTable 17.
Symptom Possible Problem Solution
AC Voltmeter defective? Check output voltage using a voltmeter.
Is wiring connection loose? Check wiring and repair.
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
Is AVR defective? Replace if necessary.
Defective Rotating Rectifi er? Check and replace.
Defective Exciter Field? Check for approximately 17.3 ohms across J & K on CN1
Is engine speed correct? Turn engine throttle lever to “High”.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Short Circuit in load? Check load and repair.
Over current? Confi rm load requirements and reduce.
Defective circuit breaker? Check and replace.
Over current Relay actuated? Confi rm load requirement and replace.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 49
Page 50
TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business offi ce or service plant.
Engine Controller Troubleshooting (MPEC)Table 18.
Symptom Possible Problem Solution
Low oil level? Fill oil level.
Low oil pressure light is on.
High coolant temperature
light is on.
Overcrank light is on.
Overspeed light is on.
Oil pressure sending unit failure? Replace oil pressure sending unit.
Time delay malfunction in controller? Refer to dealer.
Wire shorted? Inspect/repair wire.
Fan belt tension incorrect? Tighten/replace fan belt.
Air fl ow is not circulating through radiator? Clean/repair radiator grill.
Doors open? Close doors.
Exhaust leaking? Replace/repair gaskets or faulty part.
Generator being overloaded? Check/reduce load.
Thermostat failure? Replace thermostat.
Air intake blocked? Clean all air intakes.
Temperature switch failure Replace temperature switch.
No or low fuel? Fill fuel level.
Controller needs to be calibrated? Refer to dealer.
RPM engine speed too high? Adjust RPM.
Governor actuator needs to be adjusted? Adjust governor actuator.
Governor controller needs to be adjusted? Adjust governor controller.
Engine controller needs to be calibrated? Refer to dealer.
Magnetic pickup out of adjustment? Adjust magnetic pickup.
Overspeed and engine start
lights are on at same time..
PAGE 50 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Magnetic pickup dirty? Clean magnetic pickup.
Is magnetic pickup cable connected?
Inspect magnetic pickup cable and
connect cable securely.
Page 51
TROUBLESHOOTING (DIAGNOSTIC LAMP)
The engine controller of this generator diagnoses problems
that arise from the engine control system and the engine
itself. Press the diagnostic button (Figure 67) on the
diagnostic panel to determine if an engine malfunction has
occurred.
Diagnostic PanelFigure 65.
METHOD OF OPERATION
Normally, the diagnostic lamp will be 1. dimly lit when
the MPEC Control Switch is placed in the MANUAL
position.
If engine trouble occurs, the diagnostic lamp will be 2.
brightly lit as long as the control switch is left in the
manual position.
The diagnostic lamp will indicate that an engine 3.
malfunction has occurred.
NOTICE
For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual.
NOTICE
If the engine is cranked while the diagnostic switch is in
the “ON” position, the engine will not be stopped even if
the starter switch is turned to the “OFF” position. In such
case, turn the diagnostic switch to the “OFF” position.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 51
Page 52
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the help
numbers found on the back page of the manual if there are any
questions.
The contents and part numbers listed in the parts section are
subject to change
guarantee the availability of the parts listed.
Sample Parts List:
NO. PART NO. PART NAME QTY. REMARKS
1 12345 BOLT ...................... 1 ...... INCLUDES ITEMS W/
2
*
2*12347 WASHER, 3/8 IN. ... 1 ......
3 12348 HOSE ................... A/R ....MAKE LOCALLY
4 12349 BEARING ............... 1 ......S/N 2345B AND ABOVE
NO. Column
Unique Symbols - All items with same unique symbol
(*, #, +, %, or >) in the number column belong to the same
assembly or kit, which is indicated by a note in the “Remarks”
column.
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general
item, such as different size saw blade guards in use or a
part that has been updated on newer versions of the same
machine.
When ordering a part that has more than one
item number listed, check the remarks column
for help in determining the proper part to order.
without notice
WASHER, 1/4 IN. .............
. Multiquip does not
NOT SOLD SEPARATELY
MQ-45T ONLY
*
QTY. Column
Numbers Used - Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed to
describe the item can also be shown.
Assembly/Kit
unique symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
Serial Number Break
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use
used only with the specific model number or model number
variant listed. It can also be used to show a part is NOT
used on a specific model or model number variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
- All items on the parts list with the same
- Used to list an effective serial
- Indicates that the part is
PART NO. Column
Numbers Used - Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
“Make/Obtain Locally”
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
“Not Sold Separately”
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.
- Indicates that the part can be
- Indicates that an item cannot be
PAGE 52 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 53
DCA125SSIU WHISPERWATT GENERATOR WITH
ISUZU 4HK1X DIESEL ENGINE
1 to 3 units
QTY. P/N DESCRIPTION
1............0601820671 ..........AUTOMATIC VOLTAGE REGULATOR
1............0601840073 ..........RHEOSTAT VOLTAGE REGULATOR
1............0601840121 ..........KNOB, RHEOSTAT
1............M3310502203 ....... RADIATOR HOSE, UPPER
1............M3310502303 ....... RADIATOR HOSE, LOWER
5............1132402322 ..........FILTER, OIL
5............0602042590 .......... FILTER, FUEL (MAIN)
5............8980088400 .......... ELEMENT, FUEL (MAIN)
5............8980758550 .......... ELEMENT, FUEL (PRE)
5............8980714010 .......... FILTER, FUEL (FEED PUMP)
2............0605505070 ..........CAP, FUEL
5............0602046684 .......... ELEMENT, AIR CLEANER
5............0602046685 .......... ELEMENT, AIR CLEANER
1............0602122272 .......... UNIT, OIL PRESSURE
1............0602123260 ..........UNIT, WATER TEMPERATURE
1............0601810245 .......... BULB, ALARM LAMP
1............8980527130 ..........FAN BELT
1............0602202641 ..........CONTROLLER ECU
1............0601870440 .......... CIRCUIT BREAKER, 1P, 120V@ 20A
1............0601870441 .......... CIRCUIT BREAKER, 2P, 250V@ 50A
1............LY2DUS12VDC ....RELAY
SUGGESTED SPARE PARTS
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 53
Page 54
GENERATOR ASSY.
PAGE 54 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 55
GENERATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C0110001002 ROTOR ASSY 1
*1-1 FIELD ASSY 1
1-2 8131070013 FAN 1
1-3 8131611014 COUPLING DISK 8
1-4 8131015003 BALANCING PLATE ....................................1 ................PURCHASE ITEMS 1-14 AS A SET
1-5 0012112035 HEX HEAD BOLT 10
1-6 0042612000 WASHER, LOCK 10
1-7 8101026013 RECTIFIER SET PLATE .............................1 ................PURCHASE ITEMS 1-14 AS A SET
1-8 0601821349 RECTIFIER 2
1-9 0601822601 SURGE ABSORBER 1
1-10 8001020004 INSULATOR WASHER 1
1-11 8001020504 INSULATOR WASHER 1
1-12 0010110020 HEX HEAD BOLT 4
1-13 0040010000 WASHER, LOCK 4
1-14 0601000209 BALANCING WEIGHT KIT 1
1-15 0071906312 BEARING 1
2 C0130000503 STARTER ASSY 1
3 0845041804 GROMMET 2
4 8131315202 END BRACKET 1
5 8101350013 EXCITER FIELD ASSY 1
6 0012110060 HEX HEAD BOLT 4
7 0042610000 WASHER, LOCK 4
8 0041210000 WASHER, FLAT 4
9 0010112035 HEX HEAD BOLT 6
10 0040012000 WASHER, LOCK 6
11 0041212000 WASHER, FLAT 6
12 8131310104 BEARING COVER 1
13 8131312204 BEARING GASKET 1
14 8131331003 END BRACKET COVER 1
15 0017106012 HEX HEAD BOLT 10
16 8101333003 END BRACKET COVER 1
17 0010106030 HEX HEAD BOLT 2
18 0040006000 WASHER, LOCK 2
19 0041206000 WASHER, FLAT 2
20 M3163400503 COUPLING RING 1
21 0010310075 HEX HEAD BOLT 8
22 0042510000 WASHER, LOCK 8
23 0012810030 HEX HEAD BOLT 12
24 M3163600003 COUPLING ADAPTER 1
25 0012810030 HEX HEAD BOLT 12
26 0012810030 HEX HEAD BOLT 12
27 8131332014 FAN COVER 1
28 0600815000 NUT 1
29 0605000063 RUBBER SUSPENSION 2
30 0030016000 HEX NUT 2
30A 0040016000 WASHER, LOCK 2
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 55
Page 56
CONTROL BOX ASSY.
PAGE 56 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 57
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3213001702 CONTROL BOX 1
1-1 0330000210 EDGING 2
1-2 0330000280 EDGING 1
1-3 0330000180 EDGING 1
1-4 0330000160 EDGING 2
2 0601808823 CIRCUIT BREAKER, 3P 300A 1
2-1 0342604120 HEX SOCKET HEAD CAP SCREW 6
3 0021006080 MACHINE SCREW 4
4 0601823863 RELAY UNIT 2
5 0027104016 MACHINE SCREW 4
6 0601820671 AUTOMATIC VOLTAGE REGULATOR 1
7 0027105016 MACHINE SCREW 4
8 0601801124 CURRENT TRANSFORMER 3
9 0027106020 MACHINE SCREW 6
10 0601820847 OVER CURRENT RELAY 1
11 0601820848 OVER CURRENT RELAY 1
12 0027104016 MACHINE SCREW 2
12A 0207004000 HEX NUT 2
13 0601802218 FUSE HOLDER 1
13A 0601806671 FUSE, 15A 3
14 0027103016 MACHINE SCREW 2
15 0601815153 TERMINAL 1
16 0027104016 MACHINE SCREW 2
17 8121468300 INLET AIR TEMP. SENSOR ........................1 ................REPLACES P/N 0603210240
18 M3260500503 ELECTRIC PARTS SET PANEL 1
19 0016906016 HEX HEAD BOLT 4
20 8980710280 CONTROLLER ............................................1 ................REPLACES P/N 0602202686
21 M3206500604 BRACKET 1
22 0066906016 HEX HEAD BOLT 4
23 0601831205 PUSH BUTTON SWITCH 1
24 0601831330 DIAGNOSTIC SWITCH 1
25 0016906016 HEX HEAD BOLT 4
26 0601823240 RECTIFIER 1
27 0027104030 MACHINE SCREW 1
28 LY2DUS12VDC RELAY .........................................................2 ................REPLACES P/N 0601827656
28A PTF08A BASE ...........................................................2 ................REPLACES P/N 0601823109
28B PYCA1 CLIP ............................................................4 ................REPLACES P/N 0601824400
29 0027104020 MACHINE SCREW 3
30 8972177780 BAROMETRIC PRESSURE SENSOR .......1 ................REPLACES P/N 0602130220
31 0027104016 MACHINE SCREW 2
32 5825530444 RELAY STARTER ........................................1 ................REPLACES P/N 0602201402
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 57
Page 58
CONTROL BOX ASSY.
PAGE 58 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 59
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
33 0027106016 MACHINE SCREW 2
34 5825500290 RELAY .........................................................3 ................REPLACES P/N 0602201400
35 0027105016 MACHINE SCREW 3
36 8970119490 GLOW PLUG RELAY ..................................1 ................REPLACES P/N 0602202685
37 0027105016 MACHINE SCREW 2
38 M3213500604 CONTROL BOX COVER 1
39 0016906016 HEX HEAD BOLT 8
40 M3270100404 SELECTOR SWITCH 1
41 M3213601504 SWITCH BRACKET 1
42 M3213601604 SWITCH BRACKET 1
42-1 0330000170 EDGING 2
43 0027104035 MACHINE SCREW 4
43A 0207004000 HEX NUT 4
44 0027104016 MACHINE SCREW 4
44A 0207004000 HEX NUT 4
45 0016906016 HEX HEAD BOLT 6
46 M3213602404 SWITCH COVER 1
46-1 0317700180 WEATHER STRIP 1
47 M3213602304 SWITCH COVER 1
48 0016906016 HEX HEAD BOLT 10
49 0016906016 HEX HEAD BOLT 19
49A 0040506000 TOOTHED WASHER 1
50 M3223001103 CONTROL PANEL 1
51 0601807641 FREQUENCY METER, 45~65Hz 240V 1
52 0601808988 AC AMMETER, O~200A/400 1
53 0601801040 AMMETER CHANGE- OVER SWITCH 1
54 0601806859 AC VOLTMETER, O~600V 1
55 0601801041 VOLTMETER CHANGE- OVER SWITCH 1
56 0601840073 RHEOSTAT VR, 2W 1k OHM 1
57 0601840121 KNOB 1
58 0602202641 CONTROLLER 1
59 0027104040 MACHINE SCREW 2
59A 0207004000 HEX NUT 2
60 0601831340 SWITCH 1
61 0602103092 ALARM LAMP 2
61A 0601810245 BULB, ALARM LAMP 2
62 0602120095 TACHOMETER 1
63 0602122093 OIL PRESSURE GAUGE 1
64 0602123090 WATER TEMPERATURE GAUGE 1
65 0602121081 CHARGING AMMETER 1
66 0602125090 FUEL GAUGE 1
67 0601810141 PANEL LIGHT 1
68 0601831330 PANEL LIGHT SWITCH 1
69 0601831395 ENGINE SPEED SWITCH 1
70 M1223100004 STOPPER 1
71 M3223100004 STOPPER 1
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 59
Page 60
CONTROL BOX ASSY.
PAGE 60 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 61
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
72 0027105010 MACHINE SCREW 4
73 0027105010 MACHINE SCREW 4
74 M9220100004 SET SCREW 2
75 0080200007 SNAP RING 2
76 0602122272 OIL PRESSURE UNIT 1
77 M9200100004 ADAPTER 1
78 8943998582 ADAPTER....................................................1 ................REPLACES P/N 0602020220
79 0602123260 WATER TEMPERATURE UNIT 1
80 9095720140 PACKING .....................................................1 ................REPLACES P/N 0602021109
81 0602120465 TACHOMETER PICK UP 1
82 0601806644 FUSE, 30A 1
83 0601806640 FUSE, 65A 1
84 M3246702804 WIRE HARNESS GENERATOR 1
85 M3257201702 WIRE HARNESS ENGINE 1
86 M3357201802 WIRE HARNESS CONTROLLER 1
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 61
Page 62
ENGINE AND RADIATOR ASSY.
PAGE 62 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 63
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3923200134 ENGINE, ISUZU 4HK1X 1
1A 8980527130 FAN BELT ....................................................1 ................REPLACES P/N 0602015253
2 M3303200603 ENGINE FOOT 2
3 0010310025 HEX HEAD BOLT 8
4 0040010000 WASHER, LOCK 6
5 0605000060 RUBBER SUSPENSION 2
6 0030012000 HEX NUT 2
7 0040012000 WASHER, LOCK 2
8 M3923200114 RADIATOR 1
8-1 0602011029 CAP 1
8-2 M4492601304 RUBBER SEAL 2
9 M9200100904 PLUG 1
10 0150000016 O-RING 1
11 0016908020 HEX HEAD BOLT 16
12 M3310502203 RADIATOR HOSE 1
13 M3310502303 RADIATOR HOSE 1
14 0605515148 HOSE BAND 4
15 M3923200124 INTER COOLER 1
16 0132004000 PLUG 1
17 M3310502403 COOLER HOSE 1
18 M3310502503 COOLER HOSE 1
19 0605515208 HOSE BAND 2
20 0605515204 HOSE BAND 1
21 0605515207 HOSE BAND 1
22 0602046258 AIR CLEANER 1
22A 0602046684 AIR CLEANER ELEMENT 1
22B 0602046685 AIR CLEANER ELEMENT 1
23 0602040650 AIR CLEANER INDICATOR 1
24 0602040596 AIR CLEANER BAND 2
25 0016908020 HEX HEAD BOLT 4
26 0207008000 HEX NUT 4
27 M3373101003 AIR CLEANER HOSE 1
28 M3373101103 AIR CLEANER HOSE 1
29 M3326100104 BLOWBY PIPE 1
30 0605515199 HOSE BAND 1
31 0605515197 HOSE BAND 3
32 M3373100703 AIR DUCT HOSE 1
33 0191701200 BLOWBY HOSE 1
34 0605515149 HOSE BAND 2
35 0602022581 ADAPTER 1
36 0602022561 90 DEGREE ELBOW 1
37 0603306590 CONNECTOR 1
38 0603300285 ROCKNUT 1
39 0605511395 VALVE 1
40 0603306395 HOSE JOINT 1
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 63
Page 64
ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 64 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 65
ENGINE AND RADIATOR ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
41 0602021070 CAP 1
42 0269200600 DRAIN HOSE 1
43 M3323500004 OIL FILTER BRACKET 1
44 0016910025 HEX HEAD BOLT 2
45 8973243861 OIL FILTER ..................................................1 ................REPLACES P/N 0602041007
45A 1132402322 OIL FILTER CARTRIDGE ...........................1 ................REPLACES P/N 0602041221
46 0010110120 HEX HEAD BOLT 2
46A 0040010000 WASHER, LOCK 2
46B 0041210000 WASHER, FLAT 2
47 0010110150 HEX HEAD BOLT 2
47A 0040010000 WASHER, LOCK 2
47B 0041210000 WASHER, FLAT 2
50 0602022535 ADAPTER 4
51 0602022930 HOSE JOINT 4
52 0192101250 HOSE 2
53 0605515198 HOSE BAND 4
54 M3316200004 RESERVE TANK BRACKET 1
55 0016908020 HEX HEAD BOLT 2
56 M9300000203 RESERVE TANK 1
57 0602010900 RESERVE TANK CAP 1
58 M3316100504 RESERVE TANK BRACKET 1
59 0016908020 HEX HEAD BOLT 2
60 0199901050 HOSE 1
61 0193601200 HOSE 1
62 0193600450 HOSE 1
63 0605515106 HOSE BAND 3
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 65
Page 66
OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 66 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 67
OUTPUT TERMINAL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3230700003 TERMINAL BOARD 1
2 M9220100304 OUTPUT TERMINAL BOLT 5
3 M9220100404 TIE BOLT 5
4 0039316000 HEX NUT 10
5 004001600 WASHER, LOCK 15
6 0041416000 WASHER, FLAT 20
7 0016908035 HEX HEAD BOLT 5
8 M3236100903 TERMANAL COVER 1
9 M3236100104 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0027103010 MACHINE SCREW 4
11A 0030003000 HEX NUT 4
11B 0041203000 WASHER, FLAT 4
12 0027103010 MACHINE SCREW 4
12A 0030003000 HEX NUT 4
13 M9220100804 SET SCREW 2
13A 0040006000 WASHER, LOCK 2
13B 0041206000 WASHER, FLAT 2
13C 0080200005 RETAINING RING 2
14 0016906016 HEX HEAD BOLT 4
15 M3236400004 OUTLET COVER CABLE 1
16 M3236300004 CABLE OUTLET COVER SUPPORTER 1
17 0016906020 HEXHEAD BOLT 6
18 0601815194 TERMINAL BLOCK 1
19 0027104016 MACHINE SCREW 2
20 0603306775 BLIND PLUG 2
21 0027104016 MACHINE SCREW 4
22 0601870440 CIRCUIT BREAKER, 1P 20A 3
23 0601870441 CIRCUIT BREAKER, 2P 50A 3
24 M1260700504 BREAKER COVER FITTING 1
24-1 0222100100 RUBBER CUSHION 2
25 0016906020 HEX HEAD BOLT 2
26 0601812598 RECEPTACLE, GFCI 125V 20AX2 2
27 0601812538 RECEPTACLE, CS6369 250V 50A 3
28 0027104016 MACHINE SCREW 10
28A 0207004000 HEX NUT 10
29 M3236400204 COVER 1
30 0016906016 HEX HEAD BOLT 8
31 M3236100213 TERMINAL COVER 1
32 0010112045 HEX HEAD BOLT 2
33 0041212000 WASHER, FLAT 2
34 M9310200004 RUBBER STAY 2
35 0030012000 HEX NUT 2
36 M4236100604 COVER 1
37 M4236400304 BRACKET 1
38 0019206015 HEX HEAD BOLT 2
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 67
Page 68
BATTERY ASSY.
PAGE 68 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 69
BATTERY ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0602220198 BATTERY 1
2 M9310500404 BATTERY SHEET 1
3 M9103000504 BATTERY BAND 1
4 0602220921 BATTERY BOLT SET 2
5 M3346901404 BATTERY CABLE 1
5 M3346901504 BATTERY CABLE 1
7 CABLE .........................................................1 ................MAKE LOCALLY
8 0030010000 HEX NUT 1
8A 0040010000 WASHER, LOCK 1
9 0017110030 HEX HEAD BOLT 2
9A 0040510000 TOOTHED WASHER 2
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 69
Page 70
MUFFLER ASSY.
PAGE 70 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 71
MUFFLER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3330100902 MUFFLER 1
2 0016910025 HEX HEAD BOLT 4
3 M3333001403 EXHAUST PIPE 1
4 1141451840 GASKET ......................................................1 ................REPLACES P/N 0602320108
5 M3333200004 GASKET 1
6 0039308000 HEX NUT 8
7 0017110040 HEX HEAD BOLT 4
8 M3330400304 COVER 1
9 M3330400403 BRACKET 1
10 M3333300304 BRACKET 1
11 0016908020 HEX HEAD BOLT 6
12 0602326061 U-BOLT SET 2
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 71
Page 72
FUEL TANK ASSY.
PAGE 72 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 73
FUEL TANK ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3363002002 FUEL TANK 1
1-1 0605505070 FUEL TANK CAP 1
1-2 0605501076 FUEL SENDER UNIT 1
1-3 0605516090 GASKET 1
1-4 0027104015 MACHINE SCREW 5
2 M3363200204 TANK BAND 4
3 M9310500104 SUPPORTER SHEET 4
4 0016908020 HEX HEAD BOLT 2
5 0207308000 SUPER LOCK NUT 2
6 0222100150 RUBBER SHEET 4
7 M9200000003 DRAIN JOINT 1
8 M9200200004 DRAIN BOLT 1
9 0150000018 O RING 1
10 0016906020 HEX HEAD BOLT 2
11 M1363400104 DRAIN HOSE 1
12 0605515198 HOSE BAND 2
14 0016908020 HEX HEAD BOLT 4
15 8980139861 MAIN FUEL FILTER ....................................1 ................REPLACES P/N 0602042426
15A 8980088400 FUEL FILTER ELEMENT ............................1 ................REPLACES P/N 0602042515
16 8980758550 PRE. FUEL FILTER .....................................1 ................REPLACES P/N 0602042405
16A 8980758540 FUEL FILTER ELEMENT ............................1 ................REPLACES P/N 0602042516
17 8973834270 JOINT PIPE .................................................4 ................REPLACES P/N 0602042661
18 1096750951 JOINT BOLT ................................................4 ................REPLACES P/N 0602042621
19 1096300860 PACKING .....................................................8 ................REPLACES P/N 0602042641
20 0017110040 HEX HEAD BOLT 4
21 0010110070 HEX HEAD BOLT 2
21A 0040010000 WASHER, LOCK 2
21B 0041210000 WASHER, FLAT 2
22 8980682750 FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023240
22A 8980714010 FILTER, FUEL FEED PUMP 1
23 0016906025 HEX HEAD BOLT 2
24 0191301400 SUCTION HOSE 1
25 0191300800 SUCTION HOSE 1
26 0191300280 SUCTION HOSE 1
27 0191300500 SUCTION HOSE 1
28 0191303400 RETURN HOSE 1
29 0605515109 HOSE BAND 10
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 73
Page 74
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 74 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 75
ENCLOSURE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 M3413002402 BASE 1
2 M1413400004 COVER 1
3 0016908020 HEX HEAD BOLT 2
4 M3423002702 FRONT FRAME 1
4A M3493114303 ACOUSTIC SHEET 1
5 0016910025 HEX HEAD BOLT 6
6 M3423200104 FRONT FRAME COVER 1
6A M3493100304 ACOUSTIC SHEET 1
7 0019208020 HEX HEAD BOLT 14
8 M3310202203 RADIATOR SUPPORTER 1
8A M3493600504 ACOUSTIC SHEET 1
9 M3310202303 RADIATOR SUPPORTER 1
9A M3493600504 ACOUSTIC SHEET 1
10 M4310600304 RUBBER SHEET 2
11 0017112055 HEX HEAD BOLT 4
12 M3310202504 RADIATOR BRACKET 2
13 0016910025 HEX HEAD BOLT 4
14 0016910025 HEX HEAD BOLT 2
15 M3310202403 INTER COOLER BRACKET 2
16 0016910025 HEX HEAD BOLT 8
17 0017110020 HEX HEAD BOLT 8
18 M3310303303 FAN SHROUD 1
19 M3310303403 FAN SHROUD 1
20 0016908020 HEX HEAD BOLT 8
21 0016908020 HEX HEAD BOLT 4
21A 0207008000 HEX NUT 4
22 M3310303603 FAN GUARD 1
23 M3310303503 FAN GUARD 1
24 M3310303703 FAN GUARD 1
25 0016908020 HEX HEAD BOLT 16
26 M3433001302 CENTER FRAME 1
26A M3493200004 ACOUSTIC SHEET 1
27 0010114040 HEX HEAD BOLT 12
27A 0030014000 HEX NUT 12
27B 0040014000 WASHER, LOCK 24
27C 0031214000 WASHER, FLAT 24
28 M3443001802 REAR FRAME 1
28A M3493300204 ACOUSTIC SHEET 1
29 0016910030 HEX HEAD BOLT 4
29A 0040510000 TOOTHED WASHER 1
30 M3443301603 REAR COVER 1
31 M3443301703 REAR COVER DUCT 2
31A M3493308503 ACOUSTIC SHEET 1
32 0207006000 HEX NUT 9
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 75
Page 76
ENCLOSURE ASSY. (CONTINUED)
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 76 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 77
ENCLOSURE ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
33 0019208020 HEX HEAD BOLT 10
34 M3443200703 REAR DOOR 1
35 M3443600104 WINDOW PLATE 1
36 0037906000 SELF- LOCKING U NUT 10
36A 0041206000 WASHER, FLAT 10
37 M9113000002 DOOR HANDLE ASSY 1
38 0021806016 MACHINE SCREW 4
38A 0030006000 HEX NUT 4
39 M9110100204 HINGE 2
39A M9116100004 WASHER 2
40 0019208020 HEX HEAD BOLT 3
41 M9310000004 BLIND PLUG 2
42 M3463101403 ROOF PANEL 1
42A M3493508803 ACOUSTIC SHEET 1
43 M3463201902 ROOF PANEL 1
44 M3423202503 FRONT FRAME OVER COVER 1
45 0019208020 HEX HEAD BOLT 37
46 M3310600004 COVER 1
47 0019208020 HEX HEAD BOLT 4
48 M3453201602 SPLASHER PANEL 1
48A M3493426404 ACOUSTIC SHEET 1
49 0019108055 HEX HEAD BOLT 4
49A 0042308000 WASHER, LOCK 4
49B 0042408000 WASHER, FLAT 4
50 0016910025 HEX HEAD BOLT 2
51 M3453004903 SIDE DOOR 1
51A M3493425703 ACOUSTIC SHEET 1
52 M3453005003 SIDE DOOR 1
52A M3493425903 ACOUSTIC SHET 1
53 M3453005103 SIDE DOOR 1
53A M3493426104 ACOUSTIC SHEET 1
54 M3453005203 SIDE DOOR 1
54A M3493426203 ACOUSTIC SHEET 1
55 M3453303103 DUCT 2
55A M3493425804 ACOUSTIC SHEET 2
56 M3453303203 DUCT 1
56A M3493426004 ACOUSTIC SHEET 1
57 M3453302903 DUCT 1
57A M3493423904 ACOUSTIC SHEET 1
58 M3453303303 DUCT 1
58A M3493426304 ACOUSTIC SHEET 1
59 0207006000 HEX NUT 27
60 M9113000002 DOOR HANDLE ASSY 4
61 0021806016 MACHINE SCREW 16
61A 0030006000 HEX NUT 16
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 77
Page 78
ENCLOSURE ASSY. (CONTINUED)
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 78 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 79
ENCLOSURE ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
62 0600800320 MANUAL PAK 1
63 0021806016 MACHINE SCREW 4
64 M3453700004 GUTTER 1
65 0019206015 HEX HEAD BOLT 4
66 M9110100204 HINGE 4
66A M9116100004 WASHER 4
67 M9110100304 HINGE 4
67A M9116100004 WASHER 4
68 0019208020 HEX HEAD BOLT 9
69 0601850097 STOPPER 8
70 0027208025 MACHINE SCREW 8
71 M9310000004 BLIND PLUG 8
72 0016908020 HEX HEAD BOLT 1
72A 0040508000 TOOTHED WASHER 1
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 79
Page 80
RUBBER SEALS ASSY.
PAGE 80 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 81
RUBBER SEALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0229201100 RUBBER SEAL 4
2 0228900880 RUBBER SEAL 4
3 0228900990 RUBBER SEAL 3
4 0228901050 RUBBER SEAL 3
5 0228900904 RUBBER SEAL 4
6 0228900470 RUBBER SEAL 1
7 0228900530 RUBBER SEAL 1
8 0229201040 RUBBER SEAL 1
9 0228800970 RUBBER SEAL 2
10 0228800590 RUBBER SEAL 1
11 0228800630 RUBBER SEAL 1
12 0228100665 RUBBER SEAL 1
13 0228100370 RUBBER SEAL 1
14 0228100300 RUBBER SEAL 1
15 0228100365 RUBBER SEAL 1
16 0228100280 RUBBER SEAL 1
17 0228100070 RUBBER SEAL 1
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 81
Page 82
NAMEPLATE AND DECALS ASSY.
PAGE 82 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 83
NAMEPLATE AND DECALS ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1-1 M3550003003 DECAL : OPERATING PROCEDURES 1 M35000300A
1-2 M9520100304 DECAL : SAFETY INSTRUCTIONS 1 M92010030
1-3 M9520100603 DECAL : CAUTION 2 M92010060
CONTROL BOX GROUP
2-1 M3550003303 DECAL : CONTROL PANEL 1 M35000330
2-2 M3550003403 DECAL : OPERATING PANEL 1 M35000340
2-3 M9520000104 PLATE : AMMETER CHANGE- OVER SWITCH 1 M92000010
2-4 M9520000204 PLATE : VOLTMETER CHANGE- OVER SWITCH 1 M92000020
2-5 M9520000904 DECAL : DIAGNOSTIC SWITCH 1 M92000090
2-6 M9520001104 DECAL : DIAGNOSTIC BUTTON 1 M92000110
2-7 M9520100004 DECAL : WARNING ELECTRIC SHOCK HAZARD 1 M92010000
2-8 M9520100204 DECAL : CAUTION 1 M92010020A
2-9 M9520200404 DECAL : OVER CURRENT RELAY 1 M92020040
ENGINE & RADIATOR GROUP
3-1 M9500000004 DECAL : OIL DRAIN PLUG 1 M90000000
3-2 M9500100004 DECAL : WATER 1 M90010000
3-3 M9503000004 DECAL : WARNING MOVING PARTS 2 M90300000
3-4 M9503000103 DECAL : WATER - OIL CHECK 1 M90300010
3-5 M9503100004 DECAL : WARNING HOT COOLANT 1 M90310000
3-6 M9510100004 DECAL : CAUTION HOT PARTS 1 M91010000
OUTPUT TERMINAL GROUP
4-1 M1550000204 DECAL : NOTE 1 M15000020
4-2 M1550002203 DECAL : RECEPTACLE & CIRCUIT BREAKER 1 M15000220
4-3 M3550000004 DECAL : NOTE 1 M35000000
4-4 M9520000004 DECAL : GROUND 1 M92000000
4-5 M9520000504 DECAL : START CONTACT 1 M92000050
4-6 M9520100004 DECAL : WARNING ELECTRIC SHOCK HAZARD 1 M92010000
4-7 M9520100404 DECAL : DANGER HIGH VOLTAGE 1 M92010040
4-8 M9520100503 DECAL : WARNING 1 M92010050
4-9 M9520200003 DECAL : OUTPUT TERMINAL 1 M92020000
BATTERY GROUP
5-1 M9500300004 DECAL : - 1 M90030000
5-2 M9500300104 DECAL : + 1 M90030010
5-3 M9510100403 DECAL : CAUTION 1 M91010040
MUFFLER GROUP
6-1 M9503200004 DECAL : WARNING ENGINE EXHAUST 1 M90320000
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 83
Page 84
NAMEPLATE AND DECALS ASSY. (CONTINUED)
PAGE 84 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 85
NAMEPLATE AND DECALS ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
FUEL TANK GROUP
7-1 M9500500004 DECAL : DIESEL FUEL .............................................1 ........... M90050000
7-2 M9500500104 DECAL : FUEL DRAIN PLUG ...................................1 ........... M90050010
ENCLOSURE GROUP
8-1 M9510200002 DECAL : MQ ..............................................................1 ........... M91020000
8-2 060050090 EMBLEM 1
8-2A 0021106016 MACHINE SCREW 2
8-3 M3560100003 STRIPE 1
8-4 M3560100103 STRIPE 2
8-5 M3560103804 STRIPE 1
8-6 M3560100303 STRIPE 1
8-7 M3560100404 STRIPE 2
8-8 M3560100503 STRIPE 1
8-9 M3560100604 STRIPE 2
8-10 M3560103504 STRIPE 1
8-11 M3560103604 STRIPE 1
8-12 M3560103704 STRIPE 1
8-13 M3550002204 DECAL : CAUTION ....................................................1 ........... M35000220
8-14 M9510000104 DECAL : DOCUMENT BOX LOCATED .....................1 ........... M91000010
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 85
Page 86
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
Terms of payment for parts are net 30 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 condition, in the original Multiquip package (if
any), and with Multiquip part numbers
clearly marked.
6. The following items are not returnable:
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.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five 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.
9. Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted, for
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.
11. Credit issued will be applied to future
purchases only.
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 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 hereunder 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
accessories nor as to any engine not manufactured by Multiquip. Such warranties made in
connection with the sale of new, complete units
are made exclusively by a statement of warranty packaged with such units, and Multiquip
neither assumes nor 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.
Effective: February 22, 2006
PAGE 86 — DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08)
Page 87
NOTES
DCA125SSIU 50 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (12/22/08) — PAGE 87
Page 88
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600 Fax (972) 315-1847
Lewisville, TX 75057
Contact: mqpower@multiquip.com
Web: www.mqpower.com
MQ Parts Department
800-427-1244 Fax: 800-672-7877
310-537-3700 Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2008, MULTIQUIP INC.
MQ Power 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 their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifi cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published
in this publication at any time without notice and without incurring any obligations.
Manufactured for
Multiquip Inc.
by
Your Local Dealer is:
DENYO CO., LTD, JAPAN
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