Multiquip DCA-125SSJU User Manual

OPERATION AND PARTS MANUAL

MQ POWER

DCA-125SSJU

DCA-125SSJU2

PORTABLE

GENERATOR

(STANDARD)

PARTS LIST NO. 3870300064A

S/N7500469 UP TO 7500507-125SSJU

S/N FROM 7500508-125SSJU2

© COPYRIGHT 2003, MULTIQUIP INC.

Revision #4 (06/03/03)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail]

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT:

zz

z www:multiquip.com

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PAGE 2 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700
FAX: [phone] or 310-637-3284

SERVICE DEPARTMENT

800-421-1244
FAX: [phone]

TECHNICAL ASSISTANCE

800-478-1244
FAX: [phone]

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279
FAX: [phone]

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 3

DCA-125SSJU &DCA-125SSJU &

DCA-125SSJU &

DCA-125SSJU &DCA-125SSJU &
DCA-125SSJU2DCA-125SSJU2

DCA-125SSJU2

DCA-125SSJU2DCA-125SSJU2
AC GENERAAC GENERA

AC GENERA

AC GENERAAC GENERA

Here's How To Get Help .................................................... 3

Table Of Contents ............................................................. 4

Parts Ordering Procedures ...............................................5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Installation ................................................................. 14-15

Towing Safety Precaution ...............................................16

Trailer Specifications ................................................. 17-19

Generator Decals ....................................................... 20-21

General Information ........................................................22

Major Components ......................................................... 23

Generator Control Panel ................................................. 24

Engine Operating Panel (up to S/N 7500507) ................. 25

Engine Operating Panel (S/N 7500508~) ................... 26-27

Output Terminal Panel Familiarization ........................ 28-30

Load Application ............................................................. 31

Generator Outputs ..................................................... 32-33

Gauge Reading ............................................................... 33

Output Ter minal Panel Connections ........................... 34-35

Pre Setup .................................................................. 36-40

Generator Start-up Procedure (Manual) ..................... 41-44

Generator Start-up Procedure (Auto Mode) .................... 45

Generator Shut-Down Procedure .................................... 46

Maintenance .............................................................. 47-49

Trailer Brakes Maintenance ............................................ 50

Trailer Maintenance.................................................... 51-52

Trailer Wiring Diagram ..................................................... 53

Generator Wiring Diagram ............................................... 54

Engine Wiring Diagram (Ignition Switch) ......................... 55

Engine Wiring Diagram (w/ Controller) ............................ 56

Engine Troubleshooting .............................................. 58-59

Generator Troubleshooting .............................................. 60

Engine Controller Troubleshooting ................................... 61

Explanation of Code in Remarks Column ....................... 62

Suggested Spare Parts .................................................. 63

TORTOR

TOR

TORTOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Name Plate And Decals ............................................ 64-65

Generator Assembly .................................................. 66-69

Control Box Assembly ............................................... 70-73

Engine & Radiator Assembly..................................... 74-77

Engine Operating Panel Assembly ............................ 78-79

Output Terminal Assembly ......................................... 80-81

Battery Assembly ...................................................... 82-83

Muffler Assembly ...................................................... 84-85

Fuel Tank Assembly .................................................. 86-87

Enclosure Assembly ................................................. 88-91

Rubber Seal Assembly .............................................. 92-93

Terms and Condition of Sale — Parts ............................ 94

Specification and part

NOTE

number are subject to
change without notice.

WINGSWINGS

WINGS

WINGSWINGS

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

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒
❒❒

❒ Dealer name and address

❒❒
❒❒

❒ Shipping address (if different than billing address)

❒❒
❒❒

❒ Return fax number

❒❒
❒❒

❒ Applicable model number

❒❒
❒❒

❒ Quantity, part number and description of each part

❒❒
❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground
✓ FedEx or UPS Second Day or Third Day
✓ FedEx or UPS Next Day
✓ Federal Express Priority One
✓ DHL
✓ Truck

Note: Unless otherwise indicated by customer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours. We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on
hand when calling.

Parts Department

800-427-1244 Fax: [phone]

310-537-3700 Fax: [phone]

Mayco Parts

800-306-2926 Fax: [phone]

310-537-3700 Fax: [phone]

Service Department

800-478-1244 Fax: [phone]

310-537-3700

MQ Power Service Department

800-835-2551 Fax: [phone]

310-537-3700

Warranty Department

800-421-1244, Ext. 279 Fax: [phone]

310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers

800-421-1244 Fax: [phone]

310-537-3700

Place Your Parts Order Via Web or Fax

For Even More Savings!

Extra Discounts!

All parts orders which include complete part numbers
and are received by our automated web parts order
system, or by fax qualify for the following extra
discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances
when you order 10 or more
line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other
carrier.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX: [phone]
E-MAIL: [e-mail]
WWW: multiquip.com

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

DCA-125SSJU SERIES — SPECIFICATIONS

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PAGE 6 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — DIMENSIONS

Figure 1. Dimensions

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 7

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.

This Owner's Manual has been

NOTE

Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.

developed to provide complete
instructions for the safe and
efficient operation of the MQ Power

Model DCA125SSJU Series
WHISPERWATT™ GENERATOR.

HAZARD SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.

NEVER operate this equipment in a confined
area or enclosed structure that does not

provide ample free flow air.

Explosive Fuel

Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or

sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.

DANGER: You WILL be KILLED or

SERIOUSLY injured if you DO NOT follow
directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you DO NOT follow
directions.

CAUTION: You CAN be injured if you

DO NOT follow directions.

Potential hazards associated with trowel operation will be
referenced with "
this manual, and will be referenced in conjunction with Safety
"

Message Alert Symbols

Hazard Symbols

".

" which appear throughout

Burn Hazards

Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep
and

clothing

prevent injury.

fingers, hands, hair

away from all moving parts to

PAGE 8 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF

switch in the OFF position, when the
trowel is not in use.

Over Speed Conditions

NEVER tamper with the factory settings of the

engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.

This

NOTE

the surrounding environment could
be damaged if you do not follow
instructions.

generator

, other property, or

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 9

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is for
industrial use only.

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

■

:

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.

The following safety guidelines should always be used when
operating the DCA-125SSJU Series Generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment
before reading this entire manual.

■

High Temperatures – Allow the engine to cool before
performing service and maintenance functions. Contact
with

hot!

can cause serious
burns.

■

The engine of this
generator requires an
adequate free flow of

■

This equipment should not be operated by persons under 18
years of age.

■

NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel­toed boots and other protective devices required
by the job.

cooling air.
operate the generator
in any enclosed or
narrow area where free
flow of the air is restricted. If the air flow is restricted it will
cause serious damage to the generator or engine and
may cause injury to people. The generator engine gives
off DEADLY carbon monoxide gas.

■

ALWAYS make sure generator is properly grounded.

■

■

NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.

NEVER use gas piping as an electrical ground.

■

DO NOT place hands or fingers inside generator engine
compartment when engine is running.

components

NEVER

■

■

NEVER operate this equipment under the
influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident
due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and safety
decals when they become difficult read.

■

ALWAYS check the machine for loosened threads or bolts
before starting.

■

NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe

PAGE 10 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

bodily harm or even death.

ALWAYS make sure generator installation is accordance with

national and local electrical codes

■

ALWAYS have a qualified electrician perform the generator
wiring installation.

■

NEVER power cables or cords

■

NEVER
is being transfer to a load.

■

NEVER use a defective or frayed power cable. Check the
cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been
selected for the job See Table 5.

■

The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits.
performing maintenance on the generator.

stand in water

while AC power from the generator

Turn all circuit breakers OFF before

.

lay in wate

r.

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

.

■

ALWAYS make sure that electrical circuits are properly

grounded

codes before operating generator. Severe
electrocution can result from operating an ungrounded
generator.

■

ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.

■

ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.

■

ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.

DANGERDANGER

DANGER

DANGERDANGER

securely connected to the
generator’s output terminals,
insufficient tightening of the
terminal connections may cause
damage to the generator and
electrical shock.

DANGERDANGER

DANGER

DANGERDANGER

DANGERDANGER

DANGER

DANGERDANGER

per the

National Electrical Code

(NEC) and local

injury

or

death!

:

Never use damaged or worn cables when

connecting equipment to the generator.

Make sure power
connecting
cables are

WET

HANDS

:

NEVER grab or

touch a live

power cord with
wet hands , the
possibility exists

of electrical shock, electrocution, and even

death!

POWER

CORD

(POWER ON)

:

DANGERDANGER

DANGER

DANGERDANGER

by

■

Backfeed to a utility system can cause
property damage. DO NOT connect to any building's electrical
system except through an approved device or after building
main switch is opened. ALWAYS have a licensed electrician
perform the installation

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the engine

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

Maintenance Safety

■

:

electrocution

and or

:

DO NOT touch or open any of the below

mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.

is hot will result in high pressurized, boiling water to gush
out of the radiator, causing severe scalding to any persons
in the general area of the generator.

while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
to any persons in the general area of the generator.

plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.

NEVER lubricate components or attempt service on a running
machine.

■

ALWAYS allow the machine a proper
amount of time to cool before servicing.

■

NEVER touch output terminals during operation. This is
extremely dangerous. ALWAYS stop the machine and
place the circuit breaker in the “OFF” position when contact
with the output terminals is required. There exists the
possibility of

which can cause severe bodily harm or even death

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 11

electrocution, electrical shock or burn,

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace
broken parts.

!

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

■

NEVER Run engine without air filter. Severe engine
damage may occur.

■

ALWAYS service air cleaner frequently to prevent engine
malfunction.

■

ALWAYS disconnect the
performing service on the generator.

■

ALWAYS be sure the operator is familiar with proper safety
precautions when operating the generator set.

■

ALWAYS store equipment properly when not in use.

■

DO NOT leave the generator running in the
unattended.

■

DO NOT allow unauthorized people to operate this
equipment.

■

ALWAYS read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.

■

Refer to the
technical questions or information.

DANGER:DANGER:

DANGER:

DANGER:DANGER:

John Deere Engine Manual

negative battery terminal

manual mode

for engine

before

Battery

The battery contains acids that can cause injury to the eyes
and skin. To avoid eye irritation,
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.

2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
combustible gases and liquids. If
these gases and liquids come in
contact with a flame or spark, an
explosion could occur.

3. ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.

always

wear safety glasses.

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
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.

ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.

National Electrical Code

4. ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.

5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with plenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.

Transporting

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “
basic towing techniques.

clothing or skin

Towing Safety Precautions

, rinse skin or clothing

” for

PAGE 12 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Conform to

(DOT)
towing generator.

To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.

The following list of suggestions should be used when towing
your generator:

■

Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR) of 6,000 lbs.

■

ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.

Department of Transportation

Safety Towing Regulations

before

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times
when towing.

■

Raise and lock trailer wheel stand in up position when
transporting.

■

DOT Requirements include the following:

z
z

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

Connect and test electric brake operation.
Secure portable power cables in cable tray with
tie wraps.

fire extinguisher

first aid kit

.

.

■

Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety
Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle
properly.

■

ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.

■

The maximum speed for highway towing is 45 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of
terrain.

■

Place
while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.

Trailer tires should be inflated to 50 psi cold.

chock blocks

underneath wheel to prevent rolling,

■

In emergencies

nearest phone or
Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an
emergency.

always

know the location of the

keep a phone on the job site

and

fire department

.

. This

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 13

DCA-125SSJU SERIES — INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — INSTALLATION

Outdoor Installation

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

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

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.

Generator Grounding

To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.

Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.

NEC articles 250-64(b) and 250-66 set the following
grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect the

ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried aminimum of 8 ft. into the ground.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.

NOTE

When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 15

DCA-125SSJU SERIES — TOWING SAFTEY PRECAUTIONS

■

Towing Safety Precautions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 4) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.

The following list of suggestions should be used when towing
your generator:

■

Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.

■

Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety
Chain".

:

Check with your local county or state safety
towing regulations before towing your

generator.

ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.

■

ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.

■

The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.

■

Place
rolling, while parked.

■

Place
prevent tipping, while parked.

■

Use the trailer’s hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.

■

Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 3. Generator with Trailer

PAGE 16 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Explanation of Chart:

This section is to provide the user with trailer service and
maintenance information. The service and maintenance
guidelines referenced in this section apply a wide range of
trailers. Remember periodic inspection of the trailer will en­sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions when reading Table 2.

:

ALWAYS make sure the trailer is in good

operating condition. Check the tires for
proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

5. Frame Length - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug nuts.
See Table 17 and Figure 67 for lug nut tightening and
sequence.

13. Axle - Indicates the maximum weight the axle can sup­port in pounds, and the diameter of the axle expressed
in inches. Please note that some trailers have a double
axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.

1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans­porting equipment.

2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in­cluding the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 17

15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.

16. Application - Indicates which units can be employed
on a particular trailer.

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

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X05-RLRT 52-ACDONONSBL0072"421"55.BL008

FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

W07-RLRT ,06-,54-ACD

07

X07-RLRT ,06-,54-ACD

07

FX07-RLRT ,06-,54-ACD

07

FX001-RLRT 521,001-ACDLAG051CILUARDYH

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002CILUARDYH

FX022-RLRT 022-ACDLAG052CILUARDYH

FX003-RLRT 003-ACDLAG052CILUARDYH

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

LLEC

ONONSBL0091"69"05.BL008

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

ONEGRUSSBL0007"681"77.BL0002

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DAPTALF

PAGE 18 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

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W07-RLRT SSALCLLAB"2

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FX07-RLRT SSALCLLAB"2

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ELBATSUJDA2

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DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 19

DCA-125SSJU SERIES — GENERATOR DECALS

The DCA-125SSJU Series generator is equipped with a number of safety decals. These decals are provided for operator
safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on
the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 20 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR DECALS

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 21

DCA-125SSJU SERIES — GENERAL INFORMATION

DCA-125SSJU Series Familiarization
Generator

The MQ Power DCA-125SSJU Series is a 100 kW
(Figure 4) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.

Engine Operating Panel

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

z

Tachometer

z

Water Temperature Gauge

z

Oil Pressure Gauge

z

Charging Ammeter Gauge

z

Engine Throttle Handle (Up to S/N 77500507)

z

Fuel Level Gauge

z

Engine Speed Switch (S/N 7500508~)

z

Cold Starting Button

z

Panel Light

z

Panel Light Switch

z

Ignition/Preheat Switch ( Up to S/N 77500507)

z

Auto ON/OFF Engine Controller (S/N 7500508~)

Generator Control Panel

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

z

Output Voltage Adjustment Knob

z

Frequency Meter (Hz)

z

AC Ammeter (Amps)

z

AC Voltmeter (Volts)

z

Ammeter Change-Over Switch

z

Voltmeter Change-Over Switch

z

Voltage Regulator

z

Over-Current Relay

Output Terminal Panel

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

z

Three 250 VAC output receptacles (CS-6369), 50 amps

z

Three auxiliary circuit breakers, 250V @50 amps

z

Two 125 VAC output receptacles, (GFCI), 20 amps

z

Two GFCI circuit breakers, 120V@ 20amps

z

Five output terminal lugs (3Ø power)

Control Box

The “Control Box” is provided with the following:

z

3-Pole, 300 amp Main Circuit Breaker

z

Automatic Voltage Regulator

z

Current Transformer

z

Emergency Relay

generator

Open Delta Excitation System

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

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

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

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

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

Engine

The DCA-125SSJU Series Generator is powered by a
4 cycle, water cooled, turbocharged

Model

6068TF250
meet every performance requirement for the generator. Reference
Table 1 for engine specifications.

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

Mechanical Governor System

The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease, the
mechanical governor system regulates the frequency varia­tion to ±.5%. The electronic governor option increases
frequency variation to ±0.25%.

Extension Cables

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

Open-Delta

" excitation system. The open delta

Diesel

fixed ceiling

" and responds

John Deere

engine. This engine is designed to

PAGE 22 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — MAJOR COMPONENTS

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DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 23

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DCA-125SSJU SERIES — GENERATOR CONTROL PANEL

Figure 5. Generator Control Panel

The definitions below describe the controls and functions of
the DCA-125SSJU Series "
(Figure 5).

1. Main Circuit Breaker – This three-pole, 300 amp main
breaker is provided to protect the UVWO output
terminals from overload.

2. AC Ammeter – Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.

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

4. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.

5. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.

6. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the output voltage present
at the UVWO terminals.

PAGE 24 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

Generator Control Panel

Located behind the generator control panel is the

Control Box

"

electronic components required to make the genertator
function.

The “Control Box” is equipped with the following major
components:

z

Over-Current Relay

z

Voltage Rectifer

z

Starter Relay

z

Engine Controller (Computer Controlled)

z

Current Transformer

z

Voltage Selector Switch

NOTE

To restore power to the UWVO output terminals, press the

reset

button on the overcurrent relay and place the

circuit breaker in the

. This box contains some of the necessary

Remember the

relay

monitors the current
flowing from the UWVO output
terminals to the load.

In the event of a short circuit or
over current condition, it will
automatically trip the main 250
amp breaker.

closed

position (ON).

Generator

overcurrent

main

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

Figure 6. Engine Operating Panel Up To

The definitions below describe the controls and functions of
the DCA-125SSJU Series "
(Figure 6), up to S/N 7500507.

1. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.

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

3. Oil Pressure Gauge – During normal operation this
gauge be should read in the “GREEN” zone. When
starting the generator the oil pressure may read a little
bit higher, but after the engine warms up the oil pressure
should return to the green zone.

4. Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.

5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.

Engine Operating Panel

S/N 7500507

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

"

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

8. Engine Speed Throttle- This lever controls the speed

9. Ignition Switch – Turns the engine on, off or to preheat

10. Cold Starting Button – Used to warm the engine glow

11. Water Temperature Warning Light - Indicates if the

12. Oil Pressure Warning Light - This will indicate if the

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

of the engine (low or high).

the engine.

plugs in cold weather conditions. Press and hold the
engine cold starting button until the button illuminates.

coolant is low. This warning will shut off the engine.

oil pressure is too low or high. This warning will shut off
the engine.

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 25

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel From

PAGE 26 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

S/N 7500508

DCA-125SSJU SERIES — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of
the DCA-125SSJU2 "
from S/N 7500508 ~.

1. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.

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

3. Oil Pressure Gauge – During normal operation this
gauge be should read between 42 to 71 psi. When
starting the generator the oil pressure mar read a little
bit higher, but after the engine warms up the oil pressure
should return to the green zone.

4. Water Temperature Gauge – During normal operation
this gauge be should read between 165

5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.

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

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

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

8. Engine Speed Switch - This switch controls the speed
of the engine (low or high).

9. Cold Starting Button – Used to
warm the engine glow plugs in cold
weather conditions. Press and hold
the engine cold starting button until
the button illuminates.

10. Auto On/Off Engine
Controller – 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.
Any

major

controller to shutdown the
generator.

Engine Operating Panel

fault will cause the

" (Figure 7)

o

and 203oF.

During
engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " 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 "

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

A. Off/Manual/Auto Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has

E. Overspeed Shutdown – Indicates the engine is

F. Engine Running – Indicates that engine is running

cranking cycle

running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the
immediately.

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

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

temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a

major

attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration. This is considered a
fault.

running at an unsafe speed. This is considered a
fault.

at a safe operating speed.

, The MPEC will attempt to crank the

Over Speed Protection

manual

position, the generator will start

auto

position. In this position the

" mode.

major

fault.

fault.

major

major

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 27

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “

Output Terminal Panel

the following:

z

Three (3) 240V Output Receptacles, 50 amp

z

Three (3) Circuit Breakers 240V @50 amps

z

Two (2) 120V GFCI receptacles, 20 amp

z

Two (2) GFCI Circuit Breakers 120V@ 20 amps

z

One 300 Amp Main Circuit Breaker

z

Five (5) Output Terminal Lugs

” (Figure 8) is provided with

Output Terminal Panel

The

Output Terminal Panel

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.

NOTE

( Figure 8) shown below is

Terminal legs “O” and “Ground”
are considered

bonded grounds

.

Figure 8. Output Terminal Panel

PAGE 28 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

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

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

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

" (See Figure 9) in

Each 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
UVWO terminals.

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

Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face
plate cover (Figure 12). Un-lock the locking latch, and lift the
terminal cover to gain access to the plastic face plate.
Remove the screws securing the face plate to the terminal
enclosure, then lift the plastic hinged face plate.

voltage regulator control knob

Figure 11. Voltage Regulator Control Knob

increase

the voltage, turning the knob counter-

decrease

(Figure 11) on the

the voltage.

After the load wires have been securely attached to the
UVWO terminals, reinstall the plastic face plate. Place the

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

Twist Lock Dual Voltage 120/240 VAC Receptacles

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

only

be accessed

single-

terminal cover in the down position and secure the locking
latch.

phase 240/120 position.

Figure 12. Plastic Face Plate (UVWO Terminals)

Figure 10. 240 VAC Twist-Lock

Auxiliary Receptacles

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 29

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the UVWO terminal
lugs or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.

To protect the UVWO output terminals from overload, a 3­pole, 300 amp,
to switch
starting the engine.

main

circuit breaker is provided. Make sure

ALL

circuit breakers to the "OFF" position prior to

Over Current Relay

An

over current relay

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

(Figure 14) is connected to the main

reset button

Figure 14. Over Current Relay

on the over cur-

Figure 13. Connecting Loads

Maximum Output

The entire load connected to the UVWO terminal lugs, duplex
and auxiliary receptacles must not exceed 110 kw in standby or
100 kw in prime output.

PAGE 30 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — LOAD APPLICATION

Single Phase Load

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

Three Phase Load

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

frequency requirements are satisfactorily supplied by the
generator for operating the equipment.

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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's

NOTE

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

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

WATTS = VOLTAGE x AMPERAGE

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 5.

z

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.

z

When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)

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multiplied by 0.6 can be used.

z

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

When connecting ordinary power tools, a capacity of up to

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the generating set’s rated output (kW) multiplied by 0.8 can
be used.

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

CAUTION:

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0200420084.tf521.tf57.tf05

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 31

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NOTE

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

electrician
switch

must install an

isolation (transfer)

. Serious injury or death may result

licensed

without this transfer switch.

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

DCA-125SSJU SERIES — 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 15). To obtain some of

Generator Amperage

Tables 7 and 8 describe the generator’s current output capa­bility for both 1Ø-phase and 3Ø phase applications.

the voltages as listed in Table 6 (see below) will require a
fine adjustment using the

knob

located on the control panel.

voltage regulator

(VR)

control

Voltage Selector Switch

The

voltage selector

switch (Figure 15) is located above
the UVWO Hard Wire Hook-up Panel. It has been provided
for ease of voltage selection.

Figure 15. Voltage Selector Switch

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,

hold

the

red button

located at the bottom of the switch.

press

and

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CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

NEVER change the position of the

selector switch

while the engine is running.

voltage

ALWAYS place circuit breaker in the open

position before selecting voltage.

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PAGE 32 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

DCA-125SSJU SERIES — GENERATOR OUTPUTS/GAUGE READING

GFCI Receptacle Load Capability

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

Tables 9 and 10 show what amount of current is available at
the GFCI receptacles when the UVWO terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep­tacles.

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Figure 16. Voltage Selector Switch 240/139V Three Phase

Use this position for

3Ø, 208V/1Ø,120V

Position (for 3Ø, 208V, 120V voltage)

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Figure 17. AC Voltmeter

Change-Over Switch

How to Read the Output Terminal Gauge.

The gauge and selector switch 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.

When the Voltage selector switch is in the 3Ø,240/139V
position (See Figure 16), place the

Over Switch

(Figure 17) to the W-U position and the

AC Ammeter Change-Over Switch

AC Voltmeter Change-

(Figure 19) to the U or

Figure 19. AC Ammeter

Change-Over Switch

W position to read the output on the selected leg.

NOTE

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

40

20

0

60

75

A

Figure 20. AC Ammeter
(Amp reading on U lug)

The

ammeter

gauges are only active when the
UVWO terminals are in use.

and

voltmeter

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 33

DCA-125SSJU SERIES — 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
the adjustment of the

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

3Ø 240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139

position as shown in Figure 21.

Voltage Regulator Control Knob

Voltage Selector Switch

and

range

3Ø 208V/1Ø120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 24.

.

2. Connect the load wires to the UVWO terminals as shown
in Figure 25.

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

Figure 24. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position

Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown
in Figure 22.

3. Turn the voltage regulator knob (Figure 26) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

Figure 22. UVWO Terminal Lugs

240/139V Three Phase Connections

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

NOTE

Figure 23. Voltage Regulator Knob (139V/240V)

Figure 25. UVWO Terminal Lugs

3Ø-208V/120V Connections

Figure 26. Voltage Regulator Knob (208V)

To achieve a 3Ø 208V
output the voltage selector
switch must be in the 3Ø­240/139 position and the
voltage regulator must be
adjusted to 208V.

PAGE 34 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 480/277

position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown

in Figure 28.

1Ø 240V/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 30.

2. Connect the load wires to the UVWO terminals as shown
in Figure 31.

Figure 30. Voltage Selector Switch 240/120V

Single-Phase Position

Figure 28. UVWO Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 29) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

Figure 29. Voltage Regulator Knob (139V/240V)

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 35

Figure 31. UVWO Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 32) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

Figure 32. Voltage Regulator Knob (1Ø-240/120V)

DCA-125SSJU SERIES — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 300 amp,

main

circuit breaker is provided to protect the UVW output

terminals from overload. In addition two single-pole, 20 amp

GFCI

circuit breakers are provided to protect the GFCI

load

receptacles from overload. Three 50 amp
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch
the "OFF" position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 33) on the dipstick. See Table 11 for proper
selection of engine oil.

ALL

circuit breakers

circuit breakers to

Fuel Check

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Refilling the Fuel System

The DCA150SSVU genset may (if equipped with a trailer or
skid) have a
consists of an

mounted

equipped with a
skid type fuel system does not use the internal generator
fuel tank.

Fuel spillage on a
a

fire

or

explosion

wipe up the spilled fuel completely to
prevent fire hazards.
around or near the generator.

double fuel tank system

internal

fuel tank. It is also possible the genset can be

generator fuel tank, and a

skid mounted

hot!

engine can cause

. If fuel spillage occurs,

NEVER!

(Figure 34), which

smoke

trailer

fuel tank (Figure 35). The

Use the instructions in this section that applies to your type

Figure 33. Engine Oil Dipstick

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

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

z

API Service Classification CH-4

z

API Service Classification CG-4

z

API Service Classification CF-4

z

ACEA Specification E3

z

ACEA Specification E2

of fuel tank system.

ALWAYS
fuel.

DO NOT fill the fuel tanks beyond their capacities.

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

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Figure 34. Double Fuel Tank System

WARNING:WARNING:

WARNING:

WARNING:WARNING:

fill the fuel tank with clean and fresh

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

#2 diesel fuel

.

#2 diesel

PAGE 36 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — PRE-SETUP

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Figure 35. Skid Type Fuel Tank System

Refueling Procedure:

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Diesel fuel

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

1. Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 36.

and its vapors are dangerous

ALWAYS!
fuel

fill trailer tank

, before filling secondary internal tank.

first

with

#2 diesel

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALWAYS!

before refueling.

Figure 36. Only Fill on Level Ground

2. Trailer Fuel Tank First – The trailer fuel tank is the
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine.

ALWAYS

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 37

place trailer on firm level ground

fill trailer fuel tank (Figure 37) first.

Figure 37. Fuel Tank Filling Order

NOTE

NOTE

ONLY! use

refueling.

Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.

#2 diesel fuel

when

DCA-125SSJU SERIES — PRE-SETUP

3. NEVER overfill trailer fuel tank – It is important to
read the trailer fuel gauge when filling trailer fuel tank.

DO NOT wait for fuel to rise in filler neck. See Figure 38.

Figure 38. Full Trailer Tank

WARNING:WARNING:

WARNING:

WARNING:WARNING:

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

4. Once the trailer tank is full, the
can be filled (See Figure 39). Notice how the trailer
filler tube level rises when the internal tank is filled.

secondary inner tank

5. Figure 40 below reflects a full fuel system.

Figure 40. Full Fuel System

6. Fuel from the engine return line will drain into the secondary

internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.

WARNING:WARNING:

WARNING:

WARNING:WARNING:

It is recommended to only fill the internal secondary
take to 3/4 full in order to allow for fuel return, fuel
expansion, and to avoid spillage. See Figure 41
for fuel expansion.

Figure 41. Fuel Expansion

Figure 39. Filling Secondary Internal Fuel Tank

PAGE 38 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — PRE-SETUP

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.

An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

If adding coolant/antifreeze
mix to the radiator, DO
NOT remove the radiator

cap until the unit has completely cooled. The
possibility of
burns.

Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.

hot!

coolant exists which can cause severe

NOTE

Cleaning the Radiator

The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the

negative

Air Cleaner

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

Fan Belt Tension

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

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 42) when depressed with the thumb as shown
below.

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

battery terminal disconnected.

less than 50%.

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Operation Freezing Weather

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.

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Figure 42. Fan Belt Tension

NEVER!

the belts or fan while the
generator set is running.

place hands near

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 39

DCA-125SSJU SERIES — PRE-SETUP

Battery

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

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

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

Battery Cable Installation
ALWAYS be sure the battery cables (Figure 43) 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.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery
terminals when the
Heat, RUN, or START position. ALWAYS make sure
that the ignition switch is in the STOP position when
connecting the battery.

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

NOTE

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ignition

switch is in either the Pre-

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.

:

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Figure 43. Battery Connections

:

ALWAYS

terminal FIRST and reconnect
negative terminal LAST.

disconnect the negative

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 leads an electrolyte corrosion causing an
alternator failure.

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

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 (
immediately.

fuel

or

oil

) lines are defective replace them

PAGE 40 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.

ventilation when operating

away from nearby personnel.

Before Starting
Engine Operating Panel S/N 73002140 and below

ALWAYS have adequate

. Direct exhaust

CAUTION:

NEVER!
main, GFCI

in the ON (closed) position.

NOTE

manually start the engine with the

or

auailliary

circuit breakers

2. Connect the load to the

receptacles

connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
door.

3. The UVWO terminals are protected by a plastic cover,
remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.

as shown in Figure 46. These load

UVWO

terminals or

auxiliary

Steps 1 thru 19 are referenced for
Engine Operating Panels up to
S/N 7500705 (Figure 44). This unit
has a ignition key switch and a
throttle lever. It does not have an
MPEC unit.

Figure 44. Engine Operating Panel

Up to S/N 7500507

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

main, G.F.C.I.

and

aux.

circuit

breakers (Figure 45)

Figure 46. Load Connections

4. Close all engine enclosure doors (Figure 47).

Figure 47. Engine Enclosure Doors

5. When starting the generator in COLD weather conditions,
tu rn the
warm weather conditions, pre-heating is not necessary. Skip to
step 7.

ignition key

to the “PREHEAT ” position (Figure 48). In

Figure 48. Engine Ignition Switch (Pre-Heat)

Figure 45. Main, Aux. and GFCI

Circuit Breakers (OFF)

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 41

DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)

6. Press and hold the engine cold starting button
(Figure 49) until the button illuminates (ON).

Figure 49. Cold Starting Button

7. Place the voltage selector switch

in the desired voltage position
(Figure 50).

Figure 50. Voltage Selector

Switch

STARTING (MANUAL)

Engine Operating Panel up to S/N 7500507

8. Place the

engine throttle control

in the “LOW” position

(Figure 51).

11. The generator's frequency meter (Figure 54) should be
displaying the 60 cycle output frequency in HERTZ.

Figure 54. Frequency Meter (Hz)

12. The generator's AC-voltmeter (Figure 55) will display the
generator’s output in VOLTS . If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 56) to increase or decrease the
desired voltage.

Figure 55. Voltmeter

Figure 51. Engine Throttle Control

9. Turn the ignition key to the “START” position (Figure 52)
and listen for the engine to begin cranking. After the
engine starts release the ignition key.

Figure 52. Engine Ignition Switch (Start)

10. Once the engine has started, let it run for 3-5 minutes,
then turn the throttle handle control (Figure 53) to the
“HIGH” position.

Figure 53. Engine Throttle Control

Figure 56. Voltage Adjust Control Knob

13. The ammeter (Figure 57) will
indicate zero amps with no load
applied. When a load is applied,
the ammeter will indicate the
amount of current that the load is
drawing from the generator.

Figure 57. Ammeter (No Load)

14. The engine oil pressure gauge
(Figure 58) will indicate the oil
pressure (kg/ cm2) of the engine.
Under normal operating conditions
the oil pressure is approximately

Figure 58. Oil Pressure Gauge

PAGE 42 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)

15. The

16. The

coolant temperature gauge

the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (

Figure 59. Coolant Temperature Gauge

tachometer gauge

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

(Figure 60) will indicate the

(Figure 59) will indicate

Green Zone

).

18. Observe the generator's ammeter (Figure 62) and verify

it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if a load is in use.

Figure 62. Ammeter (Load)

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

Figure 60. Engine Tachometer Gauge

17. Place the
“ON” position (Figure 61).

main, GFCI

Figure 61. Main, Aux. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers in the

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 43

DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful
emissions.

ventilation when operating

away from nearby personnel.

Before Starting
Engine Operating Panel S/N 7500508~

ALWAYS have adequate

CAUTION:

NEVER!
main, GFCI

the ON (closed) position.

Steps 20 thru 31 are referenced
for Engine Operating Panel S/N
7500508~ (Figure 63). This unit
does

not

have a key ignition
switch or a throttle lever. It does
have an “
that is used in conjunction with
the MPEC unit.

engine speed switch

manually start the engine with the

or

auailliary

”

23. Set engine speed switch to “LOW ” (Figure 65).

. Direct exhaust

Figure 65. Engine Speed Switch (Low)

24. Place the Auto-Off/Reset-Manual switch in the
“MANUAL” position to start the engine (Figure 66). Once
the engine starts, let the engine run for 1-2 minutes.
Listen for any abnormal noises.

circuit breakers in

Figure 66. Auto-Off/Reset-Manual Switch

25. Once the engine is warm and the engine is running properly,
set the engine speed switch to “HIGH ” (Figure 67).

Figure 63. Engine Operating Panel

S/N 7500508~

20. Perform steps 1 through 4 in the
(page 41-42) as outlined in the

Start-up Procedure

S/N 73002140).

21. In cold weather conditions, perform step 6 in the

Starting
Generator Start-up Procedure

up to S/N 7500508). Otherwise skip to step 22.

22. Place the voltage selector switch
in the desired voltage position
(Figure 64).

Figure 64. Voltage Selector

section (page 42) as outlined in the

Switch

(Engine Operating Panel up to

Before Starting

Manual Generator

(Engine Operating Panel

section

Before

Manual

Figure 67. Engine Speed Switch (High)

26. Verify that the "Engine Running" status LED on the MPEC

unit (Figure 68) is "ON" (lit) after the engine has been started.

Figure 68. Engine Running LED (ON)

27. Continue operating the generator as outlined in steps 11
thru 19 (pages 42-43).

PAGE 44 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

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

DANGER:

switch

transfer switch.

. Serious

CAUTION:

NOTE

Before connecting this
generator to any
building’s electrical

system, a licensed

electrician must install

isolation

an

injury

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.

(transfer)

or

death

may result without this

When the generator is set in the
“AUTO” mode, the generator will

automically start

comercial power falling below a

prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.

in the event of

CAUTION:

30. Place the Off/Manual/Auto switch (Figure 70) in the
“AUTO“ position .

Figure 70. Off/Manual Auto Switch (AUTO)

31. Continue to follow the steps outlined in the “

Start-up”

The

Engine Speed Switch

to the “HIGH” position when running in the

Auto-Start

in the proper position can result in damage
to your generator when it turns on.

procedure (start at step 11, page 42).

mode. Failing to set the switch

must be set

Manual

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.

28. Perform steps 20 through 22 in the
section (page 44) as outlined in the

Procedure

29. Set the engine speed switch (Figure 69) to the “HIGH”
position.

Figure 69. Engine Speed Switch (High)

.

Before Starting

Manual Starting

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 45

DCA-125SSJU SERIES — GENERATOR SHUT-DOWN PROCEDURE

Shutdown Procedure - Ignition Switch
(Up to S/N 7500507)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 45 to the "OFF position".

2. Place the engine throttle control in the “LOW” position

(Figure 71).

Figure 71. Engine Throttle Control (Low)

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

4. Turn the Ignition Key Switch (Figure 72) to the “OFF“
position.

Shutdown Procedure - Engine Controller
(S/N 7500508~)

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 45 to the "OFF position".

2. Place the engine speed switch in the “LOW” position

(Figure 73).

Figure 73. Engine Speed Switch (Low)

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

4. Place the Auto-Off/Reset-Manual switch (Figure 74) to
the

OFF/Reset

position.

Figure 72. Engine Ignition Switch (Stop)

5. Remove all loads from the generator.

Emergency Shutdown Procedure - Ignition Switch
(Up to S/N 7500507)

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

2. Turn the ignition switch key to the “STOP”
position (Figure 72).

MAIN, GFCI

and

LOAD

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

(Figure 61) circuit

:

NEVER stop the engine suddenly except

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

5. Verify that the

6. Remove all loads from the generator.

Emergency Shutdown Procedure - Engine Controller
(S/N 7500508~)

1. To shut-down the engine in the event of an emergency,

2. Place the Auto-Off/Reset-Manual switch (Figure 74) to

Figure 74. Off/Manual Auto Switch (Off)

all

status LED on the MPEC display

(Figure 68) are "OFF" (not lit).

switch the
breakers to “OFF” position.

the “OFF/Reset“ position.

MAIN, GFCI

and

LOAD

(Figure 45) circuit

PAGE 46 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected
for deficiencies. Check for loose, missing or damaged nuts, bolts
or other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean the heavy
duty paper element with kerosene, or foam element with liquid
detergent and hot water. Wrap foam element in a cloth and
squeeze dry. For heavy duty paper element, wipe excess
kerosene with towel.

Service Daily

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

Fuel Addition

Add diesel fuel (the grade may vary according to season and
locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner
element is clogged, air intake restriction becomes greater and
the dust indicator signal shows “RED” meaning the element

the bottom of the tank. Occasionally remove the drain cock and
drain the contents. 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.

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

dusty

or

dry grass

frequently

conditions, a

if these

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 47

DCA-125SSJU SERIES — MAINTENANCE

Air Removal

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

To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.

Check Oil Level

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

Flushing Out Radiator and Replacing Coolant

z

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

z

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

z

Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO NOT
clean radiator core with any objects, such as a
screwdriver.

z

Tighten both cocks and replace the overflow tank.

z

Replace with coolant (Table 12 for correct mixture).

z

Close radiator cap tightly.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Allow engine to
radiator. Flushing the radiator while
will damage radiator.

cool

when flushing out

hot!

Replacing Oil Filter

Detach the oil filter by loosening center bolt and remove
the element together with the filter body.

Apply a film of oil to the gasket for the cartridge.
Install the filter body together with the element and fix

them by tightening the center bolt.
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.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 400
hours or so.

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

Vent any air.

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side joint
bolt. Clean the strainer with compressed air and rinse it in
the fuel oil.

Generator Storage

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

z

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

z

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

z

Clean the entire generator, internal and external.

z

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

z

Disconnect the battery.

z

Make sure engine coolant is at proper level.

z

If generator is mounted on a trailer, jack trailer up and
place on block so tires do touch the ground or remove
tires.

PAGE 48 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — MAINTENANCE

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

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

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

battery charger

These receptacles will ONLY function when commercial
power has been supplied to them (Figure 75). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 5).

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

.

jacket water heate

hot

climates there is no reason

cold

climates it is always a good

r and i

nternal

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

NOTE

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

internal battery charger

.

Figure 75. Battery Charger &

Jacket Water Heater Power Connections

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 49

DCA-125SSJU SERIES — TRAILER BRAKES MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

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

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

of

Hydraulic surge brakes (Figure 76) 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.

brakes more frequently.
Figure 74 displays the major hydraulic surge brake

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

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

Figure 76. Hydraulic Brake Components

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

Actuator

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

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

Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying

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

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

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

sure that it is functioning correctly. Never use an undersize
actuator.

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PAGE 50 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

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

Suspension

leaf suspension

The
(Figure 77) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components

CAUTION:

as detailed in Table 17.

DO NOT attempt
to repair or modify

a wheel. DO NOT
install in inner
tube to correct a leak through the rim. If the

rim is cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force and
cause serious eye or bodily injury.

Tire Wear/Inflation

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

hot!

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

Figure 77. Major Suspension Components

springs and associated components

Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.

TABLE 16. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber
or overloading.

Wheel lockup &
tire skidding.

SOLUTION

Adjust pressure to
particular load per tire
manufacturer.

Adjust pressure to
particular load per tire

manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.

Check bearing adjustment
and balance tires.

Avoid sudden stops when
possible and adjust brakes.

SHACKLE BOLT
SPRING EYE BOLT

SHOULDER TYPE
SHACKLE BOLT

CAUTION:

ALWAYS

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

wear safety glasses when removing

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TO RETAIN NUT

-

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.

.

05-XAM03-NIM

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 51

DCA-125SSJU SERIES — TRAILER MAINTENANCE

Lug Nut Torque Requirements

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

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 78. DO NOT
torque the wheel lug nuts all the way down. Tighten each
lug nut in 3 separate passes as defined by Table 18.

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

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NEVER

NOTE

PAGE 52 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

gun to tighten wheel lug nuts.

use an pneumatic air

DCA-125SSJU SERIES — TRAILER WIRING DIAGRAM

Figure 79. Trailer/Towing Vehicle Wiring Diagram

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 53

DCA-125SSJU SERIES — GENERATOR WIRING DIAGRAM

Figure 80. Generator Wiring Diagram

PAGE 54 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENGINE WIRING DIAGRAM (IGNITION SWITCH)

Figure 81. Engine Wiring Diagram(Ignition Switch)

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 55

DCA-125SSJU SERIES — ENGINE WIRING DIAGRAM (ENGINE CONTROLLER)

Figure 82. Engine Wiring Diagram (Engine Controller)

PAGE 56 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

NOTE PAGE

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 57

DCA-125SSJU SERIES — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the table shown below and on the next page for diagnosis based on the Engine Troubleshooting (Table 19).
If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTENIGNE.91ELBAT

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PAGE 58 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — TROUBLESHOOTING (ENGINE)

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?tungniniaterepip

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

.htoomstonsinoituloverenignE

?erusserp

?deggolc

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?kcuts

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?desuleufedargwoL .leufdeificepsehtesU

.tunnethgiT

.tsujdA

.ecalperroriapeR

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 59

DCA-125SSJU SERIES — TROUBLESHOOTING (GENERATOR)

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

GNITOOHSELBUORTROTARENEG.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

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

DCA-125SSJU SERIES — TROUBLESHOOTING (MPEC)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
use the table shown below for diagnosis based on the MPEC Troubleshooting (Table 21). If the problem cannot be remedied,
consult our company's business office or service plant.

GNITOOHSELBUORTRELLORTNOCENIGNE.12ELBAT

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

thgilerusserpliowoL

.nosi

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

thgilleveltnaloocwoL

.nosi

tnaloochgiH

.nosithgilerutrepmet

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

.nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

ro)s(thgilUPMfossoL

.no

?ytridpukcipcitengaM .pukcipcitengamnaelC

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 61

EXPLANATION OF CODE IN REMARKS COLUMN

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

Items Found In the “Remarks” Column

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

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

Items Found In the “Items Number” Column

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

If more than one of the same

NOTE

NOTE

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

The contents of this catalog are
subject to change without notice

, #, +, %,

*

.

PAGE 62 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — SUGGESTED SPARE PARTS

DCA-125SSJU & DCA-125SSJU2
W/JOHN DEERE 6080TF250 DIESEL ENGINE
1 TO 3 UNITS

Qty. P/N Description Remarks

1 0601820671 AUTOMATIC VOLTAGE REGULATOR
1 0601840073 RHEOSTAT VOLTAGE REGULATOR
1 0601840121 KNOB, RHEOSTAT
1 47230107 KNOB, SELECTOR SWITCH

1 M3310500003 RADIATOR HOSE, UPPER ....................... S/N 7500001TO7500307

1 M3310500403 RADIATOR HOSE, UPPER ....................... S/N 7500307~

1 M3310500103 RADIATOR HOSE, LOWER ....................... S/N 7500001TO7500307

1 M3310500503 RADIATOR HOSE, LOWER ....................... S/N 7500307~

5 0602041290 OIL FILTER
5 0602042590 FUEL FILTER
5 0602046377 AIR ELEMENT
3 0602042420 FUEL FILTER, FUEL TANK
1 0602122272 UNIT, OIL PRESSURE
1 0602123261 UNIT, WATER TEMPERATURE
1 0601810245 BULB, ALARM LAMP
1 R1234145 FAN BELT

1 0602122281 OIL SHUTDOWN SWITCH ........................ S/N 7500001TO7500507

1 0602100056 STARTER SWITCH
1 AR51481 KEY, STARTER SWITCH
1 M9310000103 ENCLOSURE CAP
1 M1483600204 ENCLOSURE CAP CHAIN ASSEMBLY
1 ECU9988NJD CONTROLLER ECU

Part number on this Suggested Spare

NOTE

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 63

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

NAMEPLATE AND DECALS

DCA-125SSJU SERIES — NAMEPLATE AND DECALS

PAGE 64 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS

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

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

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

4 M3550000102 DECAL, GENERATOR CONTROL .......................1 .............. M35000010

5 M3550000202 DECAL, ENGINE OPERATING M35000020 ........1 ..............S/N7500001 TO S/N7500507

M3550000212 DECAL, ENGINE OPERATING M35000020 ........1 .............. S/N7500508~

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

7 M9500100004 DECAL, WATER ...................................................1 .............. M90010000

8 M9500100104 DECAL, WATER DRAIN PLUG, M90010010 ....... 1 .............. S/N7500001 TO 7500307

9 M9500300004 DECAL, - .............................................................1 ..............M90030000

10 M9500300104 DECAL, + ............................................................1 .............. M900500000

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

12 M9500500104 DECAL, FUEL DRAIN PLUG ............................... 1 .............. M90050010

13 M9503000004 DECAL, WARNING ..............................................1 ..............M9030000

14 M9503000103 DECAL, WATER/OIL CHECK ...............................1 .............. M90310010

15 M9503100004 DECAL, WARNING ..............................................1 ..............M90310000

16 M9503200004 DECAL, WARNING ..............................................1 ..............M90320000

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

18 M9510200002 DECAL, MQ .........................................................1 .............. M91020000

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

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

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

22 M9520100004 DECAL, WARNING ..............................................2 ..............M92010000

23 M9520100204 DECAL, CAUTION ...............................................1 .............. M92010020A

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

25 M9520100404 DECAL, DANGER................................................1 .............. M92010040

26 M9520100503 DECAL, WARNING ..............................................1 ..............M92010050

27 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE ....1 .............. M92020010

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

29 M9560100003 STRIPE, WHISPERWATT 1
30 M3560100103 STRIPE, MQ POWER 2
31 M3560100203 STRIPE 2
32 M3560100404 STRIPE 2
33 M3560100303 STRIPE, 125 1
34 M3650100503 STRIPE, 125 1
35 M3650100604 STRIPE 3
36 M0600500090 EMBLEM 1
37 0021106015 MACHINE SCREW 2

38 M3552000103 DECAL, OPERATING PROC., M35200010 .........1 .............. S/N7500508~

39 B152000103 DECAL, CAUTION, B15200010 ........................... 2 .............. S/N7500508~

40 C95053000004 DECAL, CAUTION, C90530000 ...........................1 .............. S/N7500508~

41 9039209064 DECAL, START CONTACT, S-4468 .....................1 .............. S/N7500508~

42 TBD DECAL, FUELING PROCEDURE ........................1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 65

GENERATOR ASSY.

DCA-125SSJU SERIES — GENERATOR ASSY.

PAGE 66 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0110000002 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
1-5 0012112035 HEX. HEAD BOLT 10
1-6 0042612000 LOCK WASHER 10
1-7 8101026013 SET PLATE 1

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

1-9 0601822601 SURGE ABSORBER ................................... 1 ............ ERZM14JK621A

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

1-15 0071906312 BEARING .................................................... 1 ............ 6312 DDU C3

2 8131340213 STRATOR ASSY. 1
3 0845041804 GROMMET 2
4 8131315202 END BRACKET 1
5 8101350013 FIELD ASSY. EXCITER 1
6 0012110060 HEX. HEAD BOLT 4
7 0042610000 LOCK WASHER 4

8 031110160 PLAIN WASHER ..........................................4 ............ REPLACES 0041210000

9 0010112035 HEX. HEAD BOLT 6
10 0040012000 LOCK WASHER 6

11 031112230 PLAIN WASHER ..........................................6 ............ REPLACES 0041212000

12 8131310104 COVER, BEARING 1
13 8131312204 GASKET, BEARING 1
14 8131331003 COVER, END BRACKET 1

15 0105050616 HEX. HEAD BOLT .....................................10 ............ REPLACES 0017106012

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 67

GENERATOR ASSY. (CONT.)

DCA-125SSJU SERIES — GENERATOR ASSY. (CONT.)

PAGE 68 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — GENERATOR ASSY. (CONT.)

GENERATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

16 8101333003 COVER, END BRACKET 1
17 0010106030 HEX. HEAD BOLT 2
18 0040006000 LOCK WASHER 2

19 952404470 PLAIN WASHER ............................... 2 ......... REPLACES 0041206000

20 M3163400003 COUPLING RING 1

21 0013904044 HEX. HEAD BOLT ............................ 8 ......... S/N 7500001 TO 7500242

21 0343204150 HEX. HEAD BOLT ............................ 8 ......... S/N 7500243~

22 EM923344 LOCK WASHER ................................ 8 ......... REPLACES 0043604000

23 0070506306 BEARING ......................................... 1 ......... 6306ZZ

24 0012810030 HEX. HEAD BOLT 12

25 0012810030 HEX. HEAD BOLT .......................... 12 ......... S/N 7500001 TO 7500242

25 0010310035 HEX. HEAD BOLT .......................... 12 ......... S/N 7500243~

26 0042510000 LOCK WASHER .............................. 12 ......... S/N 7500001 TO 7500242

27 8131332003 COVER, FAN .................................... 1 ......... S/N 7500001 TO 7500242

27 8131332014 COVER, FAN .................................... 1 ......... S/N 7500243~

28 0605000063 RUBBER SUSPENSION 2
29 00300165000 HEX. NUT 2
29 0040016000 LOCK WASHER 2

30 020106050 NUT .................................................. 1 ......... REPLACES 0600815000

...................................................................... S/N 7500004~

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 69

CONTROL BOX ASSY.

DCA-125SSJU SERIES — CONTROL BOX ASSY.

PAGE 70 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3213000102 CONTROL BOX .................................................. 1 ........... S/N 7500001 TO 7500048

1 M3213000112 CONTROL BOX .................................................. 1 ........... S/N 7500049 TO 7500222

1 M3213000122 CONTROL BOX .................................................. 1 ........... S/N 7500223 TO 7500507

1 M3213000132 CONTROL BOX .................................................. 1 ........... S/N 7500508~

2 0601808813 CIRCUIT BREAKER ........................................... 1 ........... LAF363001021 3P 300A

3 0021006080 MACHINE SCREW 4

4 0601823863 RELAY UNIT ....................................................... 2 ........... MSA9013A

5 0021304015 MACHINE SCREW ............................................. 4 ........... REPLACES 0027104015

6 0601820671 AUTOMATIC VOLTAGE REGULATOR ................. 1 ........... NTA5A2DB

7 0027105010 MACHINE SCREW ............................................. 4 ........... S/N 7500001 TO 7500222

7 0027105015 MACHINE SCREW ............................................. 4 ........... S/N 7500223~

8 0601806118 CURRENT TRANSFORMER ............................. 3 ........... 814943 200/5A

9 011808015 MACHINE SCREW ............................................. 6 ........... REPLACES 0027106015

10 0601820845 OVER CURRENT RELAY ................................... 1 ........... LR2D1308

11 0601820846 OVER CURRENT RELAY ................................... 1 ........... LA7D1064

12 M1260600004 FITTING BRACKET ........................................... 1 ........... S/N 7500001 TO 7500222

13 0021304015 MACHINE SCREW ............................................. 2 ........... REPLACES 0027104015

13 0030004000 HEX. NUT ........................................................... 2 ........... REPLACES 0207004000

14 0027105020 MACHINE SCREW 4

15 M3213500003 CONTROL BOX COVER..................................... 1 ........... S/N 7500001 TO 7500048

15 M3213500013 CONTROL BOX COVER..................................... 1 ........... S/N 7500049~

16 011106015 HEX. HEAD BOLT .............................................. 4 ........... REPLACES 0016906015

17 M3923100004 SELECTOR SWITCH ......................................... 1 ........... VY125

17A 47230107 KNOB, SELECTOR SWITCH 1
18 M3276600004 SPACER 8
19 M3213600003 SWITCH BRACKET 1
20 0330000295 EDGING 2
21 M3260500004 SWITCH BOARD 1

22 0020004010 MACHINE SCREW ............................................. 4 ........... REPLACES 0021104010

23 011106015 HEX. HEAD BOLT .............................................. 6 ........... REPLACES 0016906015

24 M3213600114 SWITCH COVER ................................................ 1 ........... REPLACES M3213600104

25 011106015 HEX. HEAD BOLT .............................................. 4 ........... REPLACES 0016906015

26 011106015 HEX. HEAD BOLT ............................................ 10 ........... REPLACES 0016906015

26 0040506000 TOOTHED WASHER 1
27 M3223000103 CONTROL PANEL 1

28 0601807630 FREQUENCY METER,264250DJDJ9 ................ 1 ........... S/N 7500001 TO 7500842

28 0601807641 FREQUENCY METER,FCF-6 45-65HZ 240V ..... 1 ........... S/N 7500843~

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 71

DCA-125SSJU SERIES — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY. (CONT.)

PAGE 72 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

29 0601808953 AC AMMETER, 260240LSLS1JCA .............1 ............ S/N 7500001 TO 7500842

29 0601808988 AC AMMETER, ACF-6 - 200A,0-400A/5A ...1 ............ S/N 7500843~

30 0601801040 CHANGE-OVER SWITCH, AMMETER ....... 1 ............ SL2AS

31 0601806813 AC VOLTMETER, 260244SJSJ1 .................1 ............ S/N 7500001 TO 7500842

31 0601806859 AC AMMETER, SCF-6 0-600V ....................1 ............ S/N 7500843~

32 0601801041 CHANGE-OVER SWITCH, VOLTMETER .... 1 ............ SL2VS

33 0601840073 RHEOSTAT (VOLTAGE REGULATOR) .........1 ............ RA20A2SE102BJ 2W 1K OHM

34 0601840121 KNOB 1
35 M122310004 STOPPER 1
36 0027105015 MACHINE SCREW 2
37 0027105015 MACHINE SCREW 1
38 M9220100004 SET SCREW 1
39 0080200007 SNAP RING 1

40 0601823240 RECTIFER ................................................... 1 ............ DE4503

41 0027104020 MACHINE SCREW ......................................1 ............ S/N 7500001 TO 7500307

41 0027105020 MACHINE SCREW ......................................1 ............ S/N 7500308 TO 7500507

41 0027104020 MACHINE SCREW ......................................1 ............ S/N 7500508~

42 0602200478 EMERGENCY RELAY, 10701606023 ..........1 ............ S/N 7500001 TO 7500507

43 0027105040 MACHINE SCREW ......................................2 ............ S/N 7500001 TO 7500507

44 0602202592 STARTER RELAY ........................................ 1 ............ AT141011

45 011808015 MACHINE SCREW ......................................2 ............ REPLACES 0027106015

46 0601823240 RECTIFER, DE4503 .................................... 1 ............ S/N 7500508~

47 DYN110794000012 CONTROLLER .............................................1 ............ REPLACES 0602202599

................................................................................... S/N 7500508~

47 MPS6724 SPEED SENSOR, MAGNETIC PICK UP ... 1 ............ REPLACES 0602120485

48 0027105015 MACHINE SCREW ......................................4 ............ S/N 7500508~

49 0601823768 RELAY, LY2US12VD ....................................1 ............ S/N 7500508 TO 7500542

49 LY2US12VDC RELAY .........................................................1 ............ REPLACES 0601827656

................................................................................... S/N 7500543~

49 PTF08AE BASE, RELAY SOCKET .............................1 ............ REPLACES 0601823109

................................................................................... S/N 7500508~

49 PYCA1 CLIP ............................................................ 2 ............ REPLACES 0601824400

................................................................................... S/N 7500508~

50 0601823223 RECTIFER ................................................... 1 ............ 30D4 S/N 7500508 TO 7500542

51 0027104020 MACHINE SCREW ......................................2 ............ S/N 7500508~

52 M3246700304 WIRE HARNESS, GENERATOR 1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 73

DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

PAGE 74 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3923200004 ENGINE .............................................. 1 ................. JOHN DEERE 6068TF

1-1 0602041290 ELEMENT, OIL FILTER ...................... 1 .................RE59754A

1-2 0602042590 ELEMENT, FUEL FILTER .................. 1 ................. RE62418

1-3 0602014297 ELECTRIC HEATER ........................... 1 ................. RE29658

1-3 RE502668 ELECTRIC HEATER ASSY. .....................................S/N 7500263-

2 0602060010 BLOWER FAN .................................... 1 .................422198

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

4 0012110090 HEX. HEAD BOLT ............................... 4 ................. S/N 7500001 TO 7500003

4 0012110095 HEX. HEAD BOLT 4

5 030210250 LOCK WASHER ................................. 4 .................REPLACES 0042510000

6 M2303200303 ENGINE FOOT 2

7 0131151240 HEX HEAD BOLT ............................... 6 .................REPLACES 0010312030

8 0040012000 LOCK WASHER 6
9 0605000060 RUBBER SUSPENSION 2
10 0030012000 HEX. NUT 2
11 0040012000 LOCK WASHER 2

12 0602011988 RADIATOR, RE52824 ........................ 1 .................S/N 7500001 TO 7500003

12 0602012723 RADIATOR, C2810060000 ................ 1 ................. S/N 7500308 TO 7500952

12 0602012747 RADIATOR, C281-009-003 ................ 1 ................. S/N 7500953

12-1 0602011067 CAP ..................................................... 1 .................S/N 7500001 TO 7500307

12-1 0602011066 CAP ..................................................... 1 .................S/N 7500308~

12-2 0199101200 HOSE .................................................. 1 .................S/N 7500308~

13 0602010795 FAN COVER, C2810044210 .............. 1 .................S/N 7500001 TO 7500307

14 0013006008 HEX. HEAD BOLT ............................... 8 ................. S/N 7500001 TO 7500307

15 0043106000 PLAIN WASHER ................................. 8 ................. S/N 7500001 TO 7500307

16 M3310200204 RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 7500307

17 M3310200404 RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 7500307

18 0013006008 S/N 7500001 TO 7500307 ................. 8 .................S/N 7500001 TO 7500307

19 0043006000 LOCK WASHER ................................. 8 ................. S/N 7500001 TO 7500307

20 0043106000 PLAIN WASHER ................................. 8 ................. S/N 7500001 TO 7500307

21 011008020 HEX HEAD BOLT ............................... 8 .................REPLACES 001690820

22 0468102000 PLUG .................................................. 1 ................. S/N 7500001 TO 7500307

23 M3310500003 RADIATOR HOSE, UPPER ................ 1 .................S/N 7500001 TO 7500307

23 M3310500403 RADIATOR HOSE, UPPER ................ 1 .................S/N 7500308~

24 M3310500103 RADIATOR HOSE, LOWER............... 1 ................. S/N 7500001 TO 7500307

24 M3310500503 RADIATOR HOSE, LOWER............... 1 ................. S/N 7500308~

25 0605515148 HOSE BAND 2
26 0605515147 HOSE BAND 2
27 0605512190 HOSE JOINT 1

28 M2320300103 DRAIN JOINT ..................................... 1 .................S/N 7500001 TO 7500307

29 M9200200004 DRAIN BOLT ....................................... 1 .................S/N 7500001 TO 7500307

30 0150000018 O RING ............................................... 1 .................S/N 7500001 TO 7500307

31 0016906020 HEX HEAD BOLT ............................... 2 .................S/N 7500001 TO 7500307

32 0191300580 DRAIN HOSE ...................................... 1 ................. S/N 7500001 TO 7500307

33 0605515189 HOSE BAND ....................................... 2 .................S/N 7500001 TO 7500307

34 0602046258 AIR CLEANER .................................... 1 .................FRG100297

34 0602046377 ELEMENT, AIR CLEANER ................. 1 .................P778214

35 0602040650 INDICATOR, AIR CLEANER .............. 1 .................RBX002252

36 0603306385 NIPPLE ................................................ 1 ................. S/N 7500001 TO 7500004

37 0602040596 BAND, AIR CLEANER ........................ 1 .................P004076

38 011008020 HEX. HEAD BOLT ............................... 4 ................. REPLACES 0016908020

39 020108060 HEX, NUT ........................................... 4 ................. REPLACES 0207008000

40 M337310003 HOSE, AIR CLEANER 1

41 0605515146 HOSE BAND ....................................... 1 .................5035

42 0605515200 HOSE BAND ....................................... 1 .................5072

43 0602022563 ADAPTER 1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 75

DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE AND RADIATOR ASSY. (CONT.)

PAGE 76 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE AND RADIATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

44 0602021165 O-RING .......................................... 1 ........... S/N 7500001 TO 7500307

45 0602022561 90o ELBOW .................................... 1 ........... 3398210-10+

46 0602022562 UNION, 10WTXWLNS .................... 1 ........... S/N 7500001 TO 7500307

47 0602022792 SWIVEL, 306821010 ...................... 1 ........... S/N 7500001 TO 7500307

48 0602021070 CAP ............................................... 1 ........... 10FNTXS

49 0602021573 DRAIN HOSE ................................. 1 ........... 83610 S/N 7500001 TO 7500307

49 0269200406 DRAIN HOSE ................................. 1 ........... 83610 S/N 7500263~

50 M9300000203 RESERVE TANK 1
51 06020100900 CAP, RESERVE TANK 1
52 M3316100104 BRACKET, RESERVE TANK 1

53 0110080020 HEX.HEAD BOLT .......................... 2 ........... REPLACES 0016908020

54 0193601080 HOSE 1
55 M2260600024 RELAY BRACKET 1

56 0602202597 RELAY, AL64309 ............................ 1 ...........

56 0602202592 RELAY, AT141011 .......................... 1 ........... S/N 7500263~

57 0017106015 HEX. HEAD BOLT .......................... 1 ........... S/N 7500001 TO 7500262

57 011808015 MACHINE SCREW ........................ 2 ........... REPL. 0027106015 S/N 7500263~

58 M3313100004 RADIATOR COVER ........................ 1 ........... S/N 7500001 TO 7500307

58 M3313100204 RADIATOR COVER ........................ 1 ........... S/N 7500508~

59 0110080020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 0016908020

60 0043006000 LOCK WASHER ............................. 8 ........... S/N 7500001 TO 7500307

61 0110080020 HEX. HEAD BOLT .......................... 1 ........... REPLACES 0016908020

62 0602122281 OIL SWITCH .................................. 1 ........... 1718939011

63 0602123282 WATER SWITCH ............................ 1 ........... 1518183041

64 M9200100404 ADAPTER 1

65 M9200100704 ADAPTER ...................................... 1 ........... S/N 7500004~

66 0605511395 VALVE, XV500P8 .......................... 1 ........... S/N 7500508~

67 DYNC700250000012 ACTUATOR .................................... 1 ........... REPL. 0602150093 S/N 7500508~

68 M3356200004 STOPPER BRACKET .................... 1 ........... S/N 7500508~

69 0016910015 HEX. HEAD BOLT .......................... 1 ........... REPL. 0017110020 S/N 7500508~

70 0016906020 HEX. HEAD BOLT .......................... 1 ........... S/N 7500508~

71 0207006000 HEX. NUT ...................................... 1 ........... S/N 7500508~

72 0603306590 CONNECTOR, 10WFTXS .............. 1 ........... S/N 7500508~

73 0603300285 ROCK UNIT, 10WLN ...................... 1 ........... S/N 7500508~

74 0603306395 HOSE JOINT, 30182810 ................ 1 ........... S/N 7500508~

75 0602011491 FAN BELT 1

S/N 7500001 TO 7500262

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 77

DCA-125SSJU SERIES — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

S/N7500001 TO S/N 7500507

S/N 7500508~

PAGE 78 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1354300304 SLIDE LEVER .............................................1 ............ S/N 7500001 TO 7500507

2 M9320000004 KNOB ..........................................................1 ............ S/N 7500001 TO 7500507

3 0036003000 HEX. NUT ....................................................1 ............ S/N 7500001 TO 7500507

4 0605804150 SPRING ....................................................... 1 ............ S/N 7500001 TO 7500507

5 0041208000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 7500507

6 M1354200004 BRACKET ...................................................1 ............ S/N 7500001 TO 7500507

7 0207008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 7500507

8 0030008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 7500507

9 0605010550 SNAP PIN ................................................... 1 ............ S/N 7500001 TO 7500507

10 M3354300104 GOVERNOR ROD ....................................... 1 ............ S/N 7500001 TO 7500507

11 0602180106 BALL JOINT, LHSA8DE161 ......................... 1 ............ S/N 7500001 TO 7500507

12 0030008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 7500507

13 0602180107 BALL JOINT, LHSA8DLE161 ....................... 1 ............ S/N 7500001 TO 7500507

14 0036508000 HEX NUT .....................................................1 ............ S/N 7500001 TO 7500507

15 0207006000 HEX NUT .....................................................2 ............ S/N 7500001 TO 7500507

15 0041206000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 7500507

16A AR51481 KEY, STARTER SWITCH ............................1 ............ S/N 7500001 TO 7500507

16 0602100056 STARTER SWITCH, AR58126 .....................1 ............ S/N 7500001 TO 7500507

16 0602100028 SET NUT, R44342 .......................................1 ............ S/N 7500001 TO 7500507

16 0602100029 SET WASHER, A4827R ..............................1 ............ S/N 7500001 TO 7500507

17 0601831594 COLD STARTER BUTTON, R39554 ............ 1 ............ S/N 7500001 TO 7500342

17 0601831585 COLD STARTER BUTTON .......................... 1 ............ S/N 7500343~

17 0601831584 CAP, T55585 ................................................1 ............ S/N 7500001 TO 7500342

17 0601831588 CAP, 44053 ..................................................1 ............ S/N 7500343~

18 0602120096 TACHOMETER ............................................1 ............ 103678

19 0602122093 OIL PRESSURE GAUGE ............................1 ............ 100174

20 0602122272 UNIT, OIL PRESSURE 1

21 0602123092 WATER TEMPERATURE GAUGE ...............1 ............ 100182

22 0602123261 UNIT, WATER TEMPERATURE ...................1 ............ 0202500

23 0602121080 CHARGING AMMETER ..............................1 ............ 100158

24 0602125090 FUEL GAUGE ..............................................1 ............ 100176

25 0602103092 ALARM LAMP, PL05 ....................................2 ............ S/N 7500001 TO 7500507

25 0601810245 BULB, E10T10 DC18V ................................2 ............ S/N 7500001 TO 7500507

26 0601810141 PANEL LIGHT ..............................................1 ............ 9826800370

27 0601831330 SWITCH, PANEL LIGHT ..............................1 ............ 900001

28 ECU9988NJD ENGINE CONTROLLER ..............................1 ............ REPLACES 0602202545

29 0027104035 MACHINE SCREW ......................................2 ............ S/N 7500508~

29 0030000400 HEX. NUT ....................................................2 ............ REPL. 0207004000 S/N 7500508~

30 0601831340 SWITCH, 7562K4 ........................................ 1 ............ S/N 7500508~

30 0600500091 NAME PLATE .............................................. 1 ............ S/N 7500508~

31 0601831395 SWITCH, 7302K36 ...................................... 1 ............ S/N 7500508~

32 M3357200002 WIRE HARNESS, ENGINE .........................1 ............ S/N 7500001 TO 7500262

32 M3357200012 WIRE HARNESS, ENGINE .........................1 ............ S/N7500263 TO 7500507

32 M3359200302 WIRE HARNESS, ENGINE .........................1 ............ S/N7500508~

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 79

OUTPUT TERMINAL ASSY.

DCA-125SSJU SERIES — OUTPUT TERMINAL ASSY.

PAGE 80 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3230700003 TERMINAL PANEL 1
2 M9220100304 OUTPUT TERMINAL BOLT 5
3 M9220100404 TIE BOLT 5
4 0039316000 HEX. NUT 10
5 0040016000 LOCK WASHER 15
6 0041416000 PLAIN WASHER 20

7 0012108035 HEX. HEAD BOLT .................................... 5 .............. REPLACES 0016908035

8 M3236100303 TERMINAL COVER .................................. 1 .............. S/N 7500001 TO 7500307

8 M3236100313 TERMINAL COVER .................................. 1 .............. S/N7500308 TO S/N7500507

8 M3238100103 TERMINAL COVER .................................. 1 .............. S/N7500508~

9 M3236100104 OUTPUT WINDOW 1
10 0605010040 HINGE 2
11 0027103010 MACHINE SCREW 4

11 0207003000 HEX. NUT ................................................. 4 .............. REPLACES 0030003000

11 0041203000 PLAIN WASHER 4
12 0027103010 MACHINE SCREW 4

12 0207003000 HEX. NUT ................................................. 4 .............. REPLACES 0030003000

13 011206020 HEX. HEAD BOLT .................................... 2 .............. REPLACES 0016906020

14 0016906015 HEX. HEAD BOLT 4

15 M2236400004 CABLE OUTLET COVER ......................... 1 .............. S/N 7500001 TO 7500034

15 M3236400004 CABLE OUTLET COVER ......................... 1 .............. S/N 7500035~

16 M2236300004 SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500001 TO 7500034

16 M3236300004 SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500035~

17 011206020 HEX. HEAD BOLT .................................... 6 .............. REPLACES 0016906020

18 0601808803 CIRCUIT BREAKER ................................. 2 .............. Q0U 120B 1P 20A

19 0601808804 CIRCUIT BREAKER ................................. 3 .............. Q0U 250B 2P 50A

20 M1260700304 BREAKER FITTING COVER 1
20-1 0222100150 CUSHION RUBBER 1

21 011206020 HEX. HEAD BOLT .................................... 2 .............. REPLACES 0016906020

22 0601812597 RECEPTACLE, GF530EM 125V 20AX2 ... 2 .............. REPLACES 0601812598

23 0601811034 RECEPTACLE, CS6369 250V 50A ........... 3 .............. REPLACES 0601812538

24 0021304015 MACHINE SCREW ................................. 10 .............. REPLACES 0027104015

24 0030004000 HEX. NUT ............................................... 10 .............. REPLACES 0207004000

25 M3236100203 TERMINAL COVER .................................. 1 .............. S/N 7500001 TO 7500034

25 M3236100213 TERMINAL COVER .................................. 1 .............. S/N 7500035~

26 012212045 HEX. HEAD BOLT .................................... 2 .............. REPLACES 0010112045

27 031112230 PLAIN WASHER 2
28 M9310200004 STAY RUBBER 2
29 0030012000 NUT 2

30 M2354200004 SUPPORTER, GOVERNOR ROD ............ 1 .............. S/N 7500001 TO 7500507

31 0016906015 HEX. HEAD BOLT .................................... 2 .............. S/N 7500001 TO 7500507

32 M3455600004 PLUG ........................................................ 2 .............. S/N 7500508~

32 0603306775 PLUG ........................................................ 2 .............. S/N 7500508~

33 0021304015 MACHINE SCREW ................................... 4 .............. REPLACES 0027104015

................................................................................... S/N 7500508~

34 0601815194 TERMINAL, 6041GP02 ............................ 1 .............. S/N 7500508~

35 0021304015 MACHINE SCREW ................................... 2 .............. REPL. 0027104015 S/N 7500508~

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 81

BATTERY ASSY.

DCA-125SSJU SERIES — BATTERY ASSY.

PAGE 82 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

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

2 M9310500404 BATTERY SHEET 1
3 M9103000504 BATTERY BAND 1

4 0602220921 BATTERY BOLT SET 2

5 0040006000 LOCK WASHER 2
6 M3346900004 BATTERY CABLE 1
7 M3346900104 BATTERY CABLE 1

8 CABLE ......................................................... 1 ............ MAKE LOCALLY

9 0017112025 HEX. HEAD BOLT 1
9 0040512000 TOOTHED WASHER 1
10 0017110020 HEX. HEAD BOLT 1
10 0040510000 TOOTHED WASHER 1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 83

MUFFLER ASSY.

DCA-125SSJU SERIES — MUFFLER ASSY.

PAGE 84 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3330100002 MUFFLER ....................................................1 ............ S/N 7500001 TO 7500072

1 0602300167 MUFFLER .................................................... 1 ............ S/N 7500073~

10 0602326061 U BOLT SET 1 89547K

2 012210025 HEX. HEAD BOLT .......................................4 ............ REPLACES 0016910025

3 M3333000303 EXHAUST PIPE 1
4 0602325066 CLAMP 1
5 M3333200004 GASKET 1

6 014210040 HEX. HEAD BOLT .......................................4 ............ REPLACES 0017110040

7 M33330400304 COVER 1
8 M3330400403 BRACKET 1

9 011008020 HEX. HEAD BOLT .......................................4 ............ REPLACES 0016908020

10 0602326061 U-BOLT SET ................................................1 ............ 89547K

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 85

FUEL TANK ASSY.

DCA-125SSJU SERIES — FUEL TANK ASSY.

PAGE 86 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3363000202 FUEL TANK 1
1-1 0605505070 CAP, FUEL TANK 1
2 M3363200204 TANK BAND 2
3 M9310500104 SUPPORTERsheet 4
4 0016908020 HEX. HEAD BOLT 2

5 037908000 HEX NUT ..................................................... 2 ............ S/N 7500001 TO 7500034

5 0207308000 HEX NUT .....................................................2 ............ S/N 7500035~

5 0041208000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 7500034

6 0222100660 RUBBER SHEET 2
7 M9200000003 DRAIN JOINT 1
8 M9200200004 DRAIN BOLT 1

9 0150000018 O RING ........................................................ 1 ............ AP18

10 0016906020 HEX. HEAD BOLT 2
11 M1363400104 DRAIN HOSE 1

12 0605515198 HOSE BAND ............................................... 2 ............ 5008

13 0602042420 FUEL FILTER ..............................................1 ............ PTG15P

14 0602042601 LEAK-OFF LINE .......................................... 1 ............ RE67050

15 0191300450 SUCTION HOSE 1
16 0191301802 SUCTION HOSE 1
17 0191302200 RETURN HOSE 1

18 0605515189 HOSE BAND ............................................... 1 ............ 91004

19 0605515109 HOSE BAND ............................................... 5 ............ RS8010

20 0602220911 CLAMP ........................................................1 ............ RCT2010

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 87

ENCLOSURE ASSY.

DCA-125SSJU SERIES — ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD

PAGE 88 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3413000102 BASE ................................................ 1 ........... S/N 7500001 TO 7500307

1 M3413000112 BASE ................................................ 1 ........... S/N 7500308 TO S/N7500507

1 M3413000122 BASE ................................................ 1 ........... S/N7500508~

2 M1413400004 UNDER COVER 1

3 012210025 HEX. HEAD BOLT ............................. 2 ........... REPLACES 0016910025

4 M3423000302 FRONT FRAME ................................. 1 ........... S/N 7500001 TO S/N 7500307

4 M3423000602 FRONT FRAME ................................. 1 ........... S/N7500308~

4 M3493100203 ACOUSTIC SHEET ........................... 1 ........... S/N7500283 TO S/N7500307

4 M3493100503 ACOUSTIC SHEET ........................... 1 ........... S/N7500308~

5 012210025 HEX. HEAD BOLT ............................. 6 ........... REPLACES 0016910025

6 M3423200104 COVER, FRONT FRAME 1
6 M3493100304 ACOUSTIC SHEET 1

7 011008020 HEX. HEAD BOLT ........................... 14 ........... REPLACES 0016908020

8 M3433000102 CENTER FRAME 1
8 M3493200004 ACOUSTIC SHEET 1
9 0010114040 HEX. HEAD BOLT 12
9 0030014000 HEX. NUT 12
9 0040014000 LOCK WASHER 24

9 031114260 PLAIN WASHER .............................. 24 ........... REPLACES 0041214000

10 M3443000202 REAR FRAME ................................... 1 ........... S/N 7500001 TO S/N 7500507

10 M3443000212 REAR FRAME ................................... 1 ........... S/N7500508~

10 M3493300204 ACOUSTIC SHEET 1

11 012210025 HEX. HEAD BOLT ............................. 4 ........... REPLACES 0016910025

12 M3443300203 REAR COVER 1
13 M3443300303 DUCT, REAR COVER 1
13 M3493300303 ACOUSTIC SHEET 1
14 0207006000 HEX. NUT 12

15 011008020 HEX. HEAD BOLT ........................... 10 ........... REPLACES 0016908020

16 M3443200103 REAR DOOR ..................................... 1 ........... S/N 7500001 TO S/N 7500148

16 M3443200113 REAR DOOR ..................................... 1 ........... S/N 7500149~

17 M3443600104 WINDOW PLATE ............................... 1

18 0037906000 HEX. NUT ........................................ 10 ........... S/N 7500001 TO S/N 7500034

18 020106050 HEX. NUT ........................................ 10 ........... REPLACES 0207306000

......................................................................... S/N 7500035~

18 0041206000 PLAIN WASHER .............................. 10 ........... S/N 7500035~

18 0041206000 PLAIN WASHER .............................. 20 ........... S/N 7500001 TO S/N 7500034

19 B9114000002 DOOR HANDLE ASSY. 1

20 0027106016 MACHINE SCREW ............................ 4 ........... REPLACES 0021806015

20 020106050 HEX. NUT .......................................... 4 ........... REPLACES 0030006000

21 M9110100204 HINGE 2
22 M9116100004 WASHER 2

23 011008020 HEX. HEAD BOLT ............................. 3 ........... REPLACES 0016908020

24 M9310000004 BLIND PLUG 2

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 89

ENCLOSURE ASSY. (CONT.)

DCA-125SSJU SERIES — ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD

PAGE 90 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

25 M3463100203 ROOF PANEL 1
25 M3493500203 ACOUSTIC SHEET 1
26 M3463200102 ROOF PANEL 1
26 M3493500303 ACOUSTIC SHEET 1
27 M3463500104 OVER COVER, FRONT FRAME 1

28 011008020 HEX. HEAD BOLT ....................................37 ............. REPLACES 0016908020

29 M9310000103 ENCLOSURE CAP 1
30 M1483600204 CHAIN ASSY. 1

31 M3453200102 SPLASHER PANEL ................................... 1 ............. S/N 7500001 TO S/N 7500034

31 M3453200102 SPLASHER PANEL ................................... 1 ............. S/N 7500035 TO S/N7500307

31 M3453200122 SPLASHER PANEL ................................... 1 ............. S/N 7500308 TO S/N7500507

31 M3453200132 SPLASHER PANEL ................................... 1 ............. S/N7500508~

31 M3493401304 ACOUSTIC SHEET 1 ............. S/N 7500001 TO S/N 7500034

31 M3493401314 ACOUSTIC SHEET 1 ............. S/N 7500035~

32 011208060 HEX. HEAD BOLT ..................................... 4 ............. REPLACES 0016908055

33 012210025 HEX. HEAD BOLT ..................................... 2 ............. REPLACES 0016910025

34 M3453000703 SIDE DOOR 1
34 M3493400704 ACOUSTIC KIT A.S. FRONT DOOR (L) 1
35 M3453000603 SIDE DOOR 1
35 M3453400804 ACOUSTIC SHEET 1
36 M3453000503 SIDE DOOR (L) 1
36 M3493401004 ACOUSTIC SHEET (L) 1
37 M3453000403 SIDE DOOR (R) 1
37 M3493401104 ACOUSTIC KIT A.S. REAR DOOR (R) 1
38 M3453300303 DUCT (L) 1
38 M3493400904 ACOUSTIC KIT A.S. FRONT DUCT (L) 1
39 M3453300503 DUCT (R FRONT) 1
39 M3493401404 ACOUSTIC KIT A.S. FRONT DOOR DUCT1
40 M3453300203 DUCT (R) 1
40 M3493401204 ACOUSTIC KIT A.S. REAR DOOR DUCT 1
41 0207006000 HEX. NUT 25

42 B9114000002 DOOR HANDLE ASSY. ............................. 4 ............. REPLACES M9113000002

43 0027106016 MACHINE SCREW ...................................16 ............. REPLACES 0021806015

43 020106050 HEX. NUT ................................................. 16 ............. REPLACES 0030006000

44 M9110100204 HINGE (L) 4
45 M9110100304 HINGE (R) 4
46 M9116100004 WASHER 8

47 011008020 HEX. HEAD BOLT ..................................... 9 ............. REPLACES 0016908020

48 0601850097 DOOR STOPPER 8
49 0027208025 MACHINE SCREW 8

50 0845031504 BLIND PLUG ............................................. 8 ............. REPLACES M9310000004

51 M3453700004 DOOR BRACKET 1
52 0016906015 HEX. HEAD BOLT 4
53 016908020 HEX. HEAD BOLT 1
53 0040508000 TOOTHED WASHER 1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 91

RUBBER SEAL ASSY.

DCA-125SSJU SERIES — RUBBER SEAL ASSY.

PAGE 92 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

DCA-125SSJU SERIES — RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228900890 RUBBER SEAL 3
2 0229200810 RUBBER SEAL 1
3 0228901020 RUBBER SEAL 2
4 0228900990 RUBBER SEAL 4
5 0228900955 RUBBER SEAL 4
6 0228900470 RUBBER SEAL 2
7 0228900470 RUBBER SEAL 4
8 0229201040 RUBBER SEAL 1
9 0228800970 RUBBER SEAL 2
10 0228800590 RUBBER SEAL 1
11 0228800630 RUBBER SEAL 1
12 0228100665 RUBBER SEAL 1
13 0228100300 RUBBER SEAL 1
14 0228100370 RUBBER SEAL 1
15 0228100280 RUBBER SEAL 1
16 0228100365 RUBBER SEAL 1
17 0228100070 RUBBER SEAL 1

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 93

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

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

MINIMUM ORDER

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

RETURNED GOODS POLICY

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

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

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

a. The parts numbers and descriptions

must match the current parts price
list.

b. The list must be typed or computer

generated.

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

the return.

d. The list must reference the sales

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

e. The list must include the name and

phone number of the person request­ing the RMA.

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

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

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

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

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

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

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

b. Any parts with a limited shelf life

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

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.
e. Electrical components.
f. Paint, chemicals, and lubricants.

g. Decals and paper products.
h. Items purchased in kits.

material received that is not acceptable.

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

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

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

purchases only.

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade acces-

sories nor as to any engine not manufactured

by Multiquip. Such warranties made in connec-

tion with the sale of new, complete units are

made exclusively by a statement of warranty

packaged with such units, and Multiquip nei-

ther assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 94 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)

NOTE PAGE

DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 95

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700
FAX: [phone] or 310-637-3284

SERVICE DEPARTMENT

800-421-1244
FAX: [phone]

TECHNICAL ASSISTANCE

800-478-1244
FAX: [phone]

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279
FAX: [phone]

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail]

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT:

zz

z www:multiquip.com

zz