OPERATION AND PARTS MANUAL
MQ POWER
DCA-125SSJU
DCA-125SSJU2
PORTABLE
GENERATOR
(STANDARD)
PARTS LIST NO. 3870300064A
S/N7500469 UPTO 7500507-125SSJU
S/N FROM 7500508-125SSJU2
Revision #4 (06/03/03)
MULTIQUIPINC.
18910 WILMINGTON AVE.
PARTS DEPARTMENT:
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
FAX:310-537-3927
SERVICE DEPARTMENT:
800-835-2551
FAX:310-638-8046
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PAGE 2 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
PARTS DEPARTMENT
800-427-1244 or 310-537-3700
FAX: 800-672-7877 or 310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX: 310- 537-4259
TECHNICAL ASSISTANCE
800-478-1244
FAX: 310- 631-5032
WARRANTY DEPARTMENT
888-661-4279, or 310-661-4279
FAX: 310- 537-1173
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 3
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TABLE OF CONTENTS
DCA-125SSJU &
DCA-125SSJU2
AC GENERATOR
COMPONENT DRAWINGS
Name Plate And Decals ............................................ 64-65
Generator Assembly.................................................. 66-69
Control Box Assembly............................................... 70-73
Engine & Radiator Assembly..................................... 74-77
Engine Operating Panel Assembly ............................ 78-79
Output Terminal Assembly......................................... 80-81
Battery Assembly ...................................................... 82-83
Muffler Assembly ...................................................... 84-85
Fuel Tank Assembly .................................................. 86-87
Enclosure Assembly ................................................. 88-91
Rubber Seal Assembly .............................................. 92-93
Here's How To Get Help .................................................... 3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ...............................................5
Specifications ...................................................................6
Dimensions (Top, Side, Front) ...........................................7
Safety Message Alert Symbols .................................... 8-9
Rules for Safe Operation ........................................... 10-13
Installation ................................................................. 14-15
Towing Safety Precaution ............................................... 16
Trailer Specifications ................................................. 17-19
Generator Decals....................................................... 20-21
General Information ........................................................ 22
Major Components ......................................................... 23
Generator Control Panel ................................................. 24
Engine Operating Panel (up to S/N 7500507) ................. 25
Engine Operating Panel (S/N 7500508~) ................... 26-27
OutputTerminal Panel Familiarization ........................ 28-30
Load Application ............................................................. 31
Generator Outputs ..................................................... 32-33
Gauge Reading ............................................................... 33
OutputTerminal Panel Connections ........................... 34-35
Pre Setup .................................................................. 36-40
Generator Start-up Procedure (Manual) ..................... 41-44
Generator Start-up Procedure (Auto Mode) .................... 45
Generator Shut-Down Procedure .................................... 46
Maintenance .............................................................. 47-49
Trailer Brakes Maintenance ............................................ 50
Trailer Maintenance.................................................... 51-52
TrailerWiring Diagram ..................................................... 53
GeneratorWiring Diagram ............................................... 54
Engine Wiring Diagram (Ignition Switch) ......................... 55
EngineWiring Diagram (w/ Controller) ............................ 56
EngineTroubleshooting .............................................. 58-59
GeneratorTroubleshooting .............................................. 60
Engine ControllerTroubleshooting ................................... 61
Explanation of Code in Remarks Column ....................... 62
Suggested Spare Parts .................................................. 63
Terms and Condition of Sale — Parts ............................ 94
Specification and part
number are subject to
NOTE
change without notice.
PAGE 4 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
Dealeraccountnumber
❒
❒
❒
❒
❒
❒
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number on
hand when calling.
Parts Department
Extra Discounts!
800-427-1244
310-537-3700
Fax:800-672-7877
Fax:310-637-3284
All parts orders which include complete part numbers
and are received by our automated web parts order
system, or by fax qualify for the following extra
discounts:
Mayco Parts
800-306-2926
310-537-3700
Fax:800-672-7877
Fax:310-637-3284
Ordered
via
Standard
orders
Stock orders
($750 list and above)
Service Department
800-478-1244
310-537-3700
Fax
3%
5%
10%
10%
Fax:310-537-4259
Web
MQ Power Service Department
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
800-835-2551
310-537-3700
Fax:310-638-8046
Warranty Department
800-421-1244, Ext. 279
310-537-3700, Ext. 279
Fax:310-537-1173
No other allowances on freight shipped by any other
carrier.
Multiquip’s Main Phone Numbers
800-421-1244
310-537-3700
Fax:310-537-3927
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MULTIQUIP INC.
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
18910 WILMINGTON AVENUE
POST OFFICE BOX 6254
CARSON, CALIFORNIA 90749
310-537-3700 • 800-421-1244
FAX:310-537-3927
WWW:multiquip.com
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 5
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DCA-125SSJU SERIES — SPECIFICATIONS
Table 1. Generator Specifications
DCA-125SSJU/125SSJU2
Revolving field, self ventilated, drip proof single bearing
Star with Neutral/Zig Zag
208, 220, 240, 416, 440, 480V switchable
120, 127, 139, 240, 254, 277V switchable
137.5 KVA (110 KW)
Model
Type
Armature Connection
Voltage 3-Phase
Voltage Single-Phase
Standby Output
Prime Output
Frequency
125 KVA (100 KW)
60 Hz
1800 rpm
Speed
0.8
Power Factor
Sound Level dB (A) Full
Load at 23 feet
67
Class F
Insulation
Engine Specifications
JOHN DEERE 6068TF250
4 Cycle, water-cooled, direct injection, turbo-charged
6 cylinders
Model
Type
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
(106 mm x 127 mm)
150 HP/1800 rpm
410 cu. in. (6724 cc)
Electric
10.3 gal. (39 liters)
Coolant Capacity
Lube Oil Capacity
4.5 gal. (17 liters)
7.5 gal(28.4L)/hr at full load
4.0 gal(15.1L)/hr at 1/2 load
5.7 gal(21.6L)/hr at 3/4 load
2.3gal(8.7L)/hr at 1/4 load
Fuel Consumption
12V- 150 AH x1
#2 Diesel Fuel
Battery
Fuel
PAGE 6 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — DIMENSIONS
Figure 1. Dimensions
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 7
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DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Lethal Exhaust Gases
Engine exhaust gases contain poisonous
Safety precautions should be followed at all times when operating
this equipment. Failure to read and understand the Safety
Messages and Operating Instructions could result in injury to
yourself and others.
carbon monoxide. This gas is colorless and
odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined
area or enclosed structure that does not
provide ample free flow air.
This Owner's Manual has been
developed to provide complete
instructions for the safe and
NOTE
efficient operation of the MQ Power
Model DCA125SSJU Series
WHISPERWATT™ GENERATOR.
Explosive Fuel
Before using this GENERATOR, ensure that the operating
individual has read and understands all instructions in this
manual.
Diesel fuel is extremely flammable, and its
vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or
combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use fuel as a cleaning agent.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,
WARNING, or CAUTION.
Burn Hazards
DANGER: You WILL be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you DO NOT follow
directions.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair
and clothing away from all moving parts to
prevent injury.
CAUTION: You CAN be injured if you
DO NOT follow directions.
Potential hazards associated with trowel operation will be
referenced with "Hazard Symbols" which appear throughout
this manual, and will be referenced in conjunction with Safety
"Message Alert Symbols".
PAGE 8 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS
Accidental Starting
Respiratory Hazard
ALWAYS place the engine ON/OFF
switch in the OFF position, when the
trowel is not in use.
ALWAYS wear approved respiratory protection.
Over Speed Conditions
Sight and Hearing hazard
NEVER tamper with the factory settings of the
engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.
ALWAYS wear approved eye and hearing
protection.
Equipment Damage Messages
This generator, other property, or
the surrounding environment could
be damaged if you do not follow
instructions.
Other important messages are provided throughout this manual
to help prevent damage to your trowel, other property, or the
surrounding environment.
NOTE
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 9
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DCA-125SSJU SERIES — RULES FOR SAFE OPERATION
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
CAUTION
:
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is for
industrial use only.
The following safety guidelines should always be used when
operating the DCA-125SSJU Series Generator:
■
■
High Temperatures – Allow the engine to cool before
performing service and maintenance functions. Contact
with hot! components
can cause serious
burns.
GENERAL SAFETY
■
DO NOT operate or service this equipment
before reading this entire manual.
The engine of this
generator requires an
adequate free flow of
cooling air. NEVER
operate the generator
in any enclosed or
■
■
This equipment should not be operated by persons under 18
years of age.
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices required
by the job.
narrow area where free
flow of the air is restricted. If the air flow is restricted it will
cause serious damage to the generator or engine and
may cause injury to people. The generator engine gives
off DEADLY carbon monoxide gas.
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
■
■
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
■
ALWAYS make sure generator installation is accordance with
national and local electrical codes.
NEVER operate this equipment under the
influence or drugs or alcohol.
ALWAYS have a qualified electrician perform the generator
wiring installation.
■
■
NEVER power cables or cords lay in water.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
NEVER stand in water while AC power from the generator
is being transfer to a load.
■
■
■
■
NEVER use a defective or frayed power cable. Check the
■
■
■
■
Manufacture does not assume responsibility for any accident
due to equipment modifications.
cable for cuts in the insulation.
NEVER use a extension cord that is frayed or damaged where
the insulation has been cut.
Whenever necessary, replace nameplate, operation and safety
decals when they become difficult read.
ALWAYS make certain that proper extension cord has been
selected for the job See Table 5.
ALWAYS check the machine for loosened threads or bolts
before starting.
The electrical voltage required to operate the generator can
cause severe injury or even death through physical contact
with live circuits. Turn all circuit breakers OFF before
performing maintenance on the generator.
NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe bodily harm or even death.
PAGE 10 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — RULES FOR SAFE OPERATION
.
■
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and local
codes before operating generator.Severe injury or death! by
electrocution can result from operating an ungrounded
generator.
DANGER
:
■
■
ALWAYS be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
■
Backfeed to a utility system can cause electrocution and or
property damage. DO NOT connect to any building's electrical
system except through an approved device or after building
main switch is opened. ALWAYS have a licensed electrician
perform the installation
■
ALWAYS read, understand, and follow
procedures in Operator’s Manual before
attempting to operate equipment.
CAUTION
:
DANGER
:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
Never use damaged or worn cables when
connecting equipment to the generator.
Make sure power
c o n n e c t i n g
cables
are
Radiator
securely connected to the
generator’s output terminals,
insufficient tightening of the
terminal connections may cause
damage to the generator and
electrical shock.
1. Radiator Cap - Removing the radiator cap while the engine
is hot will result in high pressurized, boiling water to gush
out of the radiator, causing severe scalding to any persons
in the general area of the generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush out
of the coolant drain plug, therefore causing severe scalding
to any persons in the general area of the generator.
WET
HANDS
DANGER
:
NEVER grab or
touch live
a
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush out
of the oil drain plug, therefore causing severe scalding to
any persons in the general area of the generator.
power cord with
wet hands , the
possibility exists
POWER
CORD
(POWER ON)
of electrical shock, electrocution, and even
death!
Maintenance Safety
DANGER
:
■
NEVER lubricate components or attempt service on a running
machine.
■
ALWAYS allow the machine a proper
amount of time to cool before servicing.
■
NEVER touch output terminals during operation. This is
■
■
Keep the machinery in proper running condition.
extremely dangerous. ALWAYS stop the machine and
place the circuit breaker in the “OFF” position when contact
with the output terminals is required. There exists the
possibility of electrocution, electrical shock or burn,
which can cause severe bodily harm or even death!
Fix damage to the machine immediately and always replace
broken parts.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 11
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DCA-125SSJU SERIES — RULES FOR SAFE OPERATION
Battery
■
■
■
■
NEVER Run engine without air filter. Severe engine
damage may occur.
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
ALWAYS service air cleaner frequently to prevent engine
malfunction.
ALWAYS disconnect the negative battery terminal before
performing service on the generator.
ALWAYS be sure the operator is familiar with proper safety
precautions when operating the generator set.
■
■
ALWAYS store equipment properly when not in use.
1. DO NOT drop the battery. There is the possibility of risk
DO NOT leave the generator running in the manual mode
unattended.
that the battery may explode.
2. DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains
combustible gases and liquids. If
these gases and liquids come in
contact with a flame or spark, an
explosion could occur.
■
■
■
DO NOT allow unauthorized people to operate this
equipment.
ALWAYS read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
Refer to the John Deere Engine Manual for engine
technical questions or information.
3. ALWAYS keep the battery charged. If the battery is not
DANGER:
charged a buildup of combustible gas will occur.
4. ALWAYS keep battery charging and cables in good working
Pay close attention to
ventilation when operating
the generator inside
tunnels and caves. The
condition. Repair or replace all worn cables.
5. ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
engine exhaust contains noxious elements.
Engine exhaust must be routed to a
ventilated area.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
Generator Grounding
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with plenty
of water, then contact the nearest doctor or hospital, and
seek medical attention.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
Transporting
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See next page “Towing Safety Precautions” for
basic towing techniques.
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the UVWO output terminals.
PAGE 12 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — RULES FOR SAFE OPERATION
Towing Safety Precautions
■
■
Avoid sharp turns.
Trailer should be adjusted to a level position at all times
when towing.
CAUTION:
■
■
Raise and lock trailer wheel stand in up position when
transporting.
Conform to Department of Transportation
(DOT) Safety Towing Regulations before
towing generator.
DOT Requirements include the following:
z
z
Connect and test electric brake operation.
Secure portable power cables in cable tray with
tie wraps.
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.
Emergencies
■
ALWAYS know the location of the nearest fire extinguisher.
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 know the location of the nearest and first aid kit.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
In emergencies always know the location of the
nearest phone or keep a phone on the job site.
Also know the phone numbers of the nearest
ambulance, doctor and fire department. This
information will be invaluable in the case of an
emergency.
■
■
■
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 chock blocks underneath wheel to prevent rolling,
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.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 13
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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)
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DCA-125SSJU SERIES — INSTALLATION
Generator Grounding
Outdoor Installation
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
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.
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.
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.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
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.
CAUTION
:
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.
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
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.
NOTE
electrician.
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.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 15
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DCA-125SSJU SERIES — TOWING SAFTEY PRECAUTIONS
■
■
ALWAYS attach trailer’s safety chain to bumper of towing
vehicle.
Towing Safety Precautions
CAUTION
:
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your local county or state safety
towing regulations before towing your
generator.
■
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.
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.
■
■
■
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
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.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■
■
■
Avoid sharp turns to prevent rolling.
■
■
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 3. Generator with Trailer
PAGE 16 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES —TRAILER SPECIFICATIONS
5. Frame Length - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
CAUTION
:
ALWAYS make sure the trailer is in good
requirement from the tongue of the trailer.
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
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.
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 en-
sure safe towing of the equipment and will prevent damage
to the equipment and personal injury.
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.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
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.
Brakes
Tires
13. Axle - Indicates the maximum weight the axle can sup-
port 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.
Lug NutTorquing
Suspension
Electrical
Brake TroubleshootingTables
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
Use the following definitions when reading Table 2.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
16. Application - Indicates which units can be employed
on a particular trailer.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding 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
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DCA-125SSJU SERIES —TRAILER SPECIFICATIONS
Table 2. Trailer Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
SDW225,
SGW250,TLW-
300
NO
NO
NO
NO
1900LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
TRLR-10
DCA10,
TLG12, DCA-
15
NO
1900LBS
1900LBS
800LB.
FULL TILT WHEEL
TRLR-10XF
DCA10, TLG-
12, DCA15,
TLW-300
52 GAL
800LB.
FULL TILT WHEEL
TRLR-225W
WELDERS,
DA7000SS
NO
NO
NO
2200LBS
2700LBS
800LB.
FULL TILT WHEEL
TRLR-BLW400
BLW-400
ELECTRIC
W/MAST
154"
W/O 124"
55"
(78"
TALL)
800LB.
FULL TILT WHEEL
TRLR-50X
TRLR-50XF
TRLR-70W
DCA-25
DCA-25
NO
NO
2700LBS
2700LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
124"
124"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-45, -60,
70
SURGE
SURGE
SURGE
2000LB.
FLAT PAD
TRLR-70X
DCA-45, -60,
70
OPT
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
DCA-45, -60,
70
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
2000LB.
FLAT PAD
DCA-100, 125
HYDRAULIC
SURGE
2000LB.
FLAT PAD
DCA-85, 100,
125
HYDRAULIC
2000LB.
FLAT PAD
DCA-150, 180
HYDRAULIC
SURGE
5000 LB.
FLAT PAD
DCA-220
HYDRAULIC
SURGE
5000 LB.
FLAT PAD
DCA-300
HYDRAULIC
SURGE
5000 LB.
FLAT PAD
DCA-400
ELECTRIC
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
AIR
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
PAGE 18 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES —TRAILER SPECIFICATIONS
Table 2. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50" 2200# 2X2 5 LUG
3 LEAF
4 WIRE LOOM
W/
4 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2 5 LUG
2200#2X2 5 LUG
2200#2X2 5 LUG
2200#2X2 5 LUG
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
TRLR-BLW
400
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-50X
2" BALL CLASS
B78-13LRC
B78-13LRC
3500lbs.
2-3/8"
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
4 POLE
RUBBER FLAT
TRLR-50XF 2" BALL CLASS
3500lbs.
2-3/8"
4 POLE
RUBBER FLAT
TRLR-70W
TRLR-70X
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE
RUBBER FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE
RUBBER FLAT
TRLR-70XF 2" BALL CLASS
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE
RUBBER FLAT
3" ADJUSTABLE
TRLR-100XF ADJUSTABLE 2-
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
5/6 OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2- ST225/75R15D
(2)-6000lbs 6 LUG
(2)-6000lbs 8 LUG
(2)-7000lbs 8 LUG
(2)-6000lbs 8 LUG
5/6 OPT 3" EYE
RADIAL (4)
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
(3)-7000lb- 8 LUG
s.
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
(3)-10000l- 8 LUG
bs
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
(3)-10000l- 8 LUG
bs
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 19
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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)
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DCA-125SSJU SERIES — GENERATOR DECALS
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 21
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DCA-125SSJU SERIES — GENERAL INFORMATION
Open Delta Excitation System
DCA-125SSJU Series Familiarization
Generator
The DCA-125SSJU Series Generator is equipped with the state
of the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
The MQ Power DCA-125SSJU Series is a 100 kW generator
(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.
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.
Engine Operating Panel
The“Engine Operating Panel”is provided with the following:
z
z
z
z
z
z
z
z
z
z
z
z
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
EngineThrottle Handle (Up to S/N 77500507)
Fuel Level Gauge
Engine Speed Switch (S/N 7500508~)
Cold Starting Button
Panel Light
Panel Light Switch
Ignition/Preheat Switch ( Up to S/N 77500507)
Auto ON/OFF Engine Controller (S/N 7500508~)
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 "fixed ceiling" and responds
according the demands of the required load.
Generator Control Panel
The“Generator Control Panel”is provided with the following:
Engine
z
z
z
z
z
z
z
z
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
The DCA-125SSJU Series Generator is powered by a
4 cycle, water cooled, turbocharged John Deere
Model 6068TF250 Diesel engine. This engine is designed to
meeteveryperformancerequirementforthegenerator.Reference
Table 1 for engine specifications.
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
In keeping with MQ Power's policy of constantly improving its
products, the specifications quoted herein are subject to change
without prior notice.
Over-Current Relay
OutputTerminal Panel
Mechanical Governor System
The “Output Terminal Panel” is provided with the following:
The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease, the
mechanical governor system regulates the frequency varia-
tion to .5%. The electronic governor option increases
frequency variation to 0.25%.
z
z
z
z
z
Three 250VAC output receptacles (CS-6369), 50 amps
Three auxiliary circuit breakers, 250V @50 amps
Two 125 VAC output receptacles, (GFCI), 20 amps
Two GFCI circuit breakers, 120V@ 20amps
Five output terminal lugs (3Ø power)
Extension Cables
Control Box
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.
The “Control Box” is provided with the following:
z
z
z
z
3-Pole, 300 amp Main Circuit Breaker
Automatic Voltage Regulator
CurrentTransformer
Emergency Relay
PAGE 22 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — MAJOR COMPONENTS
Table 3. Generator Major Components
ITEM NO.
DESCRIPTION
Muffler Assembly
1
2
3
4
5
6
7
8
9
Engine Assembly
Enclosure Assembly
Generator Assembly
Output Terminal Assembly
Fuel Tank Assembly
Battery Assembly
Generator Control Panel Assembly
Engine Operating Panel Assembly
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
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the genertator
function.
The definitions below describe the controls and functions of
the DCA-125SSJU Series "Generator Control Panel "
(Figure 5).
1. Main Circuit Breaker – This three-pole, 300 amp main
breaker is provided to protect the UVWO output
terminals from overload.
The “Control Box” is equipped with the following major
components:
z
z
z
z
z
z
Over-Current Relay
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
CurrentTransformer
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.
Voltage Selector Switch
Remember the overcurrent
relay monitors the current
flowing from the UWVO output
terminals to the load.
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.
NOTE
In the event of a short circuit or
over current condition, it will
automatically trip the main 250
amp breaker.
5. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
6. Frequency Meter – Indicates the output frequency in
To restore power to the UWVO output terminals, press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
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)
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DCA-125SSJU SERIES — ENGINE OPERATING PANEL
Figure 6. Engine Operating Panel Up To S/N 7500507
6. Fuel Gauge - Indicates amount of diesel fuel available.
The definitions below describe the controls and functions of
the DCA-125SSJU Series "Engine Operating Panel "
(Figure 6), up to S/N 7500507.
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.
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.
8. Engine SpeedThrottle- This lever controls the speed
of the engine (low or high).
2. Panel Light Switch – When activated will turn on control
panel light.
9. Ignition Switch – Turns the engine on, off or to preheat
the engine.
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.
10. 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.
11. Water Temperature Warning Light - Indicates if the
4. WaterTemperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
coolant is low. This warning will shut off the engine.
12. Oil Pressure Warning Light - This will indicate if the
oil pressure is too low or high. This warning will shut off
the engine.
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.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 25
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DCA-125SSJU SERIES — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel From S/N 7500508
PAGE 26 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-125SSJU2 " Engine Operating Panel " (Figure 7)
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.
During cranking cycle ,The MPEC will attempt to crank the
engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the controller will shutdown the engine by
initializing the "Over Speed Protection" mode.
Also the engine controller will 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.
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.
A. Off/Manual/Auto Switch – This switch controls the
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 manual position, the generator will start
immediately.
4. WaterTemperature Gauge – During normal operation
this gauge be should read between 165o and 203oF.
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.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the auto position. In this position the
generator will monitor the AC line output from the
building's power source.
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.
B. Low Oil Pressure – Indicates the engine pressure
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a major fault.
C. High Coolant Temperature – Indicates the engine
8. Engine Speed Switch - This switch controls the speed
temperature has exceeded 215 F. The engine
°
of the engine (low or high).
temperature is detected using variable resistive values
from the temperature sending unit.This is considered
a major fault.
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.
D. Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration.This is considered a major
fault.
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 fault will cause the
controller to shutdown the
generator.
E. Overspeed Shutdown – Indicates the engine is
running at an unsafe speed.This is considered a major
fault.
F.
Engine Running – Indicates that engine is running
at a safe operating speed.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 27
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DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
The Output Terminal Panel ( Figure 8) shown below is
located on the right-hand side (left from control panel) of the
generator. Lift up on the cover to gain access to receptacles
and terminal lugs.
The “Output Terminal Panel ” (Figure 8) is provided with
the following:
z
z
z
z
z
z
Three (3) 240V Output Receptacles, 50 amp
Three (3) Circuit Breakers 240V @50 amps
Two (2) 120V GFCI receptacles, 20 amp
Two (2) GFCI Circuit Breakers 120V@ 20 amps
One 300 Amp Main Circuit Breaker
Terminal legs “O” and “Ground”
NOTE
are considered bonded grounds.
Five (5) Output Terminal Lugs
Figure 8. Output Terminal Panel
PAGE 28 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
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.
120VAC GFCI Receptacles
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker.These breakers are located directly above the GFCI
receptacles. Remember the load output (current) of both
GFCI receptacles is dependent on the load requirements of
the UVWO terminals.
Turn the voltage regulator control knob (Figure 11) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob counter-
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11. Voltage Regulator Control Knob
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.
After the load wires have been securely attached to the
UVWO terminals, reinstall the plastic face plate. Place the
terminal cover in the down position and secure the locking
latch.
Figure 9. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC 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 only be accessed
when the voltage selector switch is placed in the single-
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
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DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
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.
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
To protect the UVWO output terminals from overload, a 3-
pole, 300 amp, main circuit breaker is provided. Make sure
to switch ALL circuit breakers to the "OFF" position prior to
starting the engine.
Figure 14. Over Current Relay
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.
Figure 13. Connecting Loads
PAGE 30 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — LOAD APPLICATION
Three Phase Load
Single Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
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
starting system of the equipment.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
If wattage is not given on the equipment's
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate 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.
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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.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 4 below
when connecting loads.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
Table 4. Power Factor by Load
Type
of Load
Power Factor
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Fluorescent lamps, mecury lamps
Electronic devices, communication
equipment
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation (transfer)
switch. Serious injury or death may result
without this transfer switch.
Table 5. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
Current in
Amperes
At 120
Volts
At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybedeterminedbymultiplying
voltage by amperage by 1.732.
7.5
10
15
20
900
1200
1800
2400
NOTE
50 ft.
CAUTION: Equipment damage can result from low voltage.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 31
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DCA-125SSJU SERIES — GENERATOR OUTPUTS
Generator OutputVoltages
Generator Amperage
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
Tables 7 and 8 describe the generator’s current output capa-
bility for both 1Ø-phase and 3Ø phase applications.
Table 7. Generator Ampere
Ratings — 1Ø
kW
240V
120V
166
208
250
291
333
375
417
500
Voltage Selector Switch
20
83
25
104
225
145
166
187
208
250
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.
30
35
40
45
50
60 (Max)
Table 8. Generator Ampere Ratings — 3Ø
kW
20
25
30
35
40
45
50
60
208V
240V
480V
59
60
30
87
75
38
104
121
139
156
174
208
90
45
Figure 15. Voltage Selector Switch
105
120
136
152
181
53
60
Voltage Selector Switch Locking Button
68
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
76
99
CAUTION:
NEVER change the position of the voltage
selector switch while the engine is running.
ALWAYS place circuit breaker in the open
position before selecting voltage.
Table 6. Voltages Available
Three Phase
(Switchable)
208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
Single Phase
(Switchable)
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DCA-125SSJU SERIES — GENERATOR OUTPUTS/GAUGE READING
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the UVWO ter-
minals or the 3 twist lock auxilliary receptacles.
Use this position for
3Ø, 208V/1Ø,120V
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 recep-
tacles.
Table 9. GFCI Receptacle Load Capability
KVA in Use
(UVWO Terminals)
Available Load Current
(AMPS)
3Ø 240/480V
GFCI Duplex NEMA
5-20R 120V
Figure 16. Voltage Selector Switch 240/139V Three Phase
Position (for 3Ø, 208V, 120V voltage)
82
0
77.8
73.7
69.5
65.4
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 10. GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
Available Load Current
(AMPS)
1Ø 240/120V
GFCI Duplex NEMA
5-20R 120V
Figure 18 AC Voltmeter
Gauge
Figure 17. AC Voltmeter
Change-Over Switch
60
0
58.8
57.6
56.4
55.2
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
(Volt reading on W-U Lug)
40
20
60
0
75
How to Read the OutputTerminal Gauge.
The gauge and selector switch on the control panel DO NOT
effect the generator output. They are provided to help ob-
serve how much power is being supplied, produced at the
UVWO terminals lugs.
A
Figure 19. AC Ammeter
Change-Over Switch
Figure 20. AC Ammeter
(Amp reading on U lug)
When the Voltage selector switch is in the 3Ø,240/139V
position (See Figure 16), place the AC Voltmeter Change-
Over Switch (Figure 17) to the W-U position and the
AC Ammeter Change-Over Switch (Figure 19) to the U or
W position to read the output on the selected leg.
The ammeter and voltmeter
gauges are only active when the
UVWO terminals are in use.
NOTE
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 33
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DCA-125SSJU SERIES — OUTPUTTERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V UVWOTerminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 24.
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are de-
pendent on the position of the Voltage Selector Switch and
the adjustment of the Voltage Regulator Control Knob.
Use this position for
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
Figure 24. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position
3Ø 240/139 UVWOTerminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as shown
in Figure 25.
Figure 21. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the UVWO terminals as shown
in Figure 22.
Figure 25. UVWO Terminal Lugs
3Ø-208V/120V Connections
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
Figure 26. Voltage Regulator Knob (208V)
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V
output the voltage selector
switch must be in the 3Ø-
240/139 position and the
voltage regulator must be
adjusted to 208V.
NOTE
Figure 23. Voltage Regulator Knob (139V/240V)
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DCA-125SSJU SERIES — OUTPUTTERMINAL PANEL CONNECTIONS
3Ø 480/277 UVWOTerminal Output Voltages
1Ø 240V/120V UVWOTerminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 30.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 30. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the UVWO terminals as shown 2. Connect the load wires to the UVWO terminals as shown
in Figure 28. in Figure 31.
Figure 28. UVWO Terminal Lugs
240/139V Three Phase Connections
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.
3. Turn the voltage regulator knob (Figure 29) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 32. Voltage Regulator Knob (1Ø-240/120V)
Figure 29. Voltage Regulator Knob (139V/240V)
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 35
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DCA-125SSJU SERIES — PRE-SETUP
Fuel Check
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
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch ALL circuit breakers to
the "OFF" position prior to starting the engine.
DANGER:
Fuel spillage on a hot! engine can cause
a fire or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER! smoke
around or near the generator.
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.
Refilling the Fuel System
The DCA150SSVU genset may (if equipped with a trailer or
skid) have a double fuel tank system (Figure 34), which
consists of an internal generator fuel tank, and a trailer
mounted fuel tank. It is also possible the genset can be
equipped with a skid mounted fuel tank (Figure 35). The
skid type fuel system does not use the internal generator
fuel tank.
Use the instructions in this section that applies to your type
of fuel tank system.
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.
ALWAYS fill the fuel tank with clean and fresh #2 diesel
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.
Other types of motor oils may be substituted if they meet
the following requirements:
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API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
Table 11. Recommended Motor Oil
Figure 34. Double Fuel Tank System
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 15W-40
WARNING:
ONLY properly trained personel who have
read and understand this section should refill
the double fuel tank system.
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 5W-30
Below 5° C (-15°)
SAE 30 OR SAE 0W-30
Use #2 diesel fuel.
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DCA-125SSJU SERIES — PRE-SETUP
CAUTION:
ALWAYS! fill trailer tank first with #2 diesel
fuel, before filling secondary internal tank.
Figure 35. Skid Type FuelTank System
Refueling Procedure:
DANGER:
Diesel fuel and its vapors are dangerous
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.
WARNING:
Figure 37. Fuel Tank Filling Order
ALWAYS! place trailer on firm level ground
before refueling.
ONLY! use #2 diesel fuel when
refueling.
NOTE
Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.
NOTE
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 fill trailer fuel tank (Figure 37) first.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 37
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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.
5. Figure 40 below reflects a full fuel system.
Figure 38. Full Trailer Tank
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:
DO NOT OVER-FILL fuel system. Leave room
for fuel expansion . Fuel expands when heated.
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.
4. Once the trailer tank is full, the secondary inner tank
can be filled (See Figure 39). Notice how the trailer
filler tube level rises when the internal tank is filled.
Figure 41. Fuel Expansion
Figure 39. Filling Secondary Internal FuelTank
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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.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
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 battery terminal disconnected.
CAUTION:
If adding coolant/antifreeze
mix to the radiator, DO
NOT remove the radiator
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.
cap until the unit has completely cooled.The
possibility of hot! coolant exists which can cause severe
burns.
Fan BeltTension
A slack fan belt may contribute to overheating, or to
Day-to-day addition of coolant is done from the recovery insufficient charging of the battery. Inspect the fan belt for
tank.When adding coolant to the radiator, DO NOT remove damage and wear and adjust it in accordance with the John
the radiator cap until the unit has completely cooled. See Deere Engine Owner's Manual.
Table 12 for engine, radiator, and recovery tank coolant
The fan belt tension is proper if the fan belt bends 10 to 15
capacities. Make sure the coolant level in the recovery tank
mm (Figure 42) when depressed with the thumb as shown
is always between the "H" and the "L" markings.
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
6.1 Gal. (23 Liters)
2 Quarts (1.9 Liters)
Figure 42. Fan Belt Tension
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
NEVER! place hands near
the belts or fan while the
generator set is running.
Table 13. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
Vol %
Anti-Freeze
°C
-24
-37
°F
°C
°F
40
50
-12
-34
106
108
222
226
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DCA-125SSJU SERIES — PRE-SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
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.
terminals when the ignition switch is in either the Pre-
Heat, RUN, or START position. ALWAYS make sure
that the ignition switch is in the STOP position when
connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or
malfunctions. Always keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
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.
NOTE
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
CAUTION
:
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.
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Alternator
CAUTION
:
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.
ALWAYS disconnect the negative
terminal FIRST and reconnect
negative terminal LAST.
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.
Figure 43. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
2. Connect the load to the UVWO terminals or auxiliary
WARNING:
receptacles as shown in Figure 46. These load
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.
The engine's exhaust contains harmful
emissions. ALWAYS have adequate
ventilation when operating. Direct exhaust
away from nearby personnel.
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.
Before Starting
Engine Operating Panel S/N 73002140 and below
CAUTION:
NEVER! manually start the engine with the
main, GFCI or auailliary circuit breakers
in the ON (closed) position.
NOTE
Figure 46. Load Connections
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.
4. Close all engine enclosure doors (Figure 47).
Figure 44. Engine Operating Panel
Up to S/N 7500507
Figure 47. Engine Enclosure Doors
1. Place the main, G.F.C.I. and aux. circuit breakers (Figure 45)
in the “OFF” position prior to starting the engine.
5. When starting the generator in COLD weather conditions,
turn the ignitionkey to the“PREHEAT ”position (Figure 48).In
warm weather conditions, pre-heating is not necessary.Skip to
step 7.
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
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DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
6. Press and hold the engine cold starting button 11. The generator's frequency meter (Figure 54) should be
(Figure 49) until the button illuminates (ON).
displaying the 60 cycle output frequency in HERTZ.
Figure 49. Cold Starting Button
Figure 54. Frequency Meter (Hz)
7. Place the voltage selector switch
in the desired voltage position
(Figure 50).
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 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 55. Voltmeter
(Figure 51).
Figure 51. Engine Throttle Control
Figure 56. Voltage Adjust Control Knob
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.
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)
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.
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
Figure 53. Engine Throttle Control
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DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
15. The coolant temperature gauge (Figure 59) will indicate 18. Observe the generator's ammeter (Figure 62) and verify
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
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 59. Coolant Temperature Gauge
Figure 62. Ammeter (Load)
16. The tachometer gauge (Figure 60) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 60. Engine Tachometer Gauge
17. Place the main, GFCI, and aux. circuit breakers in the
“ON” position (Figure 61).
Figure 61. Main, Aux. and GFCI
Circuit Breakers (ON)
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 43
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DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (MANUAL)
23. Set engine speed switch to “LOW ” (Figure 65).
WARNING:
The engine's exhaust contains harmful
emissions. ALWAYS have adequate
ventilation when operating. Direct exhaust
away from nearby personnel.
Figure 65. Engine Speed Switch (Low)
Before Starting
Engine Operating Panel S/N 7500508~
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.
CAUTION:
NEVER! manually start the engine with the
main, GFCI or auailliary circuit breakers in
the ON (closed) position.
Steps 20 thru 31 are referenced
Figure 66. Auto-Off/Reset-Manual Switch
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 “engine speed switch”
that is used in conjunction with
the MPEC unit.
25. Once the engine is warm and the engineisrunningproperly,
set the engine speed switch to “HIGH ” (Figure 67).
Figure 67. Engine Speed Switch (High)
Figure 63. Engine Operating Panel
26. Verify that the "Engine Running" status LED on the MPEC
unit (Figure 68) is "ON" (lit) after the engine has been started.
S/N 7500508~
20. Perform steps 1 through 4 in the Before Starting section
(page 41-42) as outlined in the Manual Generator
Start-up Procedure (Engine Operating Panel up to
S/N 73002140).
21. In cold weather conditions, perform step 6 in the Before
Starting section (page 42) as outlined in the Manual
Generator Start-up Procedure (Engine Operating Panel
up to S/N 7500508). Otherwise skip to step 22.
Figure 68. Engine Running LED (ON)
27. Continue operating the generator as outlined in steps 11
thru 19 (pages 42-43).
22. Place the voltage selector switch
in the desired voltage position
(Figure 64).
Figure 64. Voltage Selector
Switch
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DCA-125SSJU SERIES — GENERATOR START-UP PROCEDURE (AUTO MODE)
DANGER:
Before connecting this
generator to any
building’s electrical
system, a licensed
CAUTION:
The Engine Speed Switch must be set
to the “HIGH” position when running in the
Auto-Start mode. Failing to set the switch
in the proper position can result in damage
to your generator when it turns on.
electrician must install
an isolation (transfer)
switch. Serious injury or death may result without this
transfer switch.
30. Place the Off/Manual/Auto switch (Figure 70) in the
CAUTION:
“AUTO“ position .
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.
Figure 70. Off/Manual Auto Switch (AUTO)
When the generator is set in the
“AUTO” mode, the generator will
automically start in the event of
31. Continue to follow the steps outlined in the “Manual
Start-up” procedure (start at step 11, page 42).
comercial power falling below a
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
NOTE
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 Before Starting
section (page 44) as outlined in the Manual Starting
Procedure.
29. Set the engine speed switch (Figure 69) to the “HIGH”
position.
Figure 69. Engine Speed Switch (High)
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 45
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DCA-125SSJU SERIES — GENERATOR SHUT-DOWN PROCEDURE
Shutdown Procedure - Ignition Switch
(Up to S/N 7500507)
Shutdown Procedure - Engine Controller
(S/N 7500508~)
To shutdown the generator use the following procedure:
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers 1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 45 to the "OFF position". as shown in Figure 45 to the "OFF position".
2. Place the engine throttle control in the “LOW” position 2. Place the engine speed switch in the “LOW” position
(Figure 71).
(Figure 73).
Figure 73. Engine Speed Switch (Low)
Figure 71. Engine Throttle Control (Low)
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
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
4. Turn the Ignition Key Switch (Figure 72) to the “OFF“
the OFF/Reset position.
position.
Figure 74. Off/Manual Auto Switch (Off)
Figure 72. Engine Ignition Switch (Stop)
5. Verify that the all status LED on the MPEC display
(Figure 68) are "OFF" (not lit).
5. Remove all loads from the generator.
6. Remove all loads from the generator.
Emergency Shutdown Procedure - Ignition Switch
(Up to S/N 7500507)
Emergency Shutdown Procedure - Engine Controller
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 61) circuit
breakers to “OFF” position.
(S/N 7500508~)
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 45) circuit
breakers to “OFF” position.
2. Turn the ignition switch key to the “STOP”
position (Figure 72).
2. Place the Auto-Off/Reset-Manual switch (Figure 74) to
the “OFF/Reset“ position.
CAUTION
:
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.
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DCA-125SSJU SERIES — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter *1
Clean Air Filter
X
X
X
X
Drain Bottom of Fuel Tank
ENGINE
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
X
Clean Radiator and Check Coolant Protection Level
Test Fuel Injection Nozzle
Replace Air Filter Element
Check all Hoses and Clamps
Check Valve Clearance
X
X
X
X
X
Check Injection Nozzle
X
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
X
GENERATOR
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
General Inspection
Service Daily
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.
If the engine is operating in very dusty or dry grass conditions, a
clogged air cleaner will result.This can lead to a loss of power,
excessive carbon buildup in the combustion chamber and high
fuel consumption. Change air cleaner more frequently if these
conditions exists.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
Fuel Addition
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.
Add diesel fuel (the grade may vary according to season and
locations). Always pour through the mesh filter.
RemovingWater from the FuelTank
After prolonged use, water and other impurities accumulate in
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.
Air Cleaner with Dust Indicator
This indicator is attached to the air cleaner.When the air cleaner
element is clogged, air intake restriction becomes greater and
the dust indicator signal shows “RED” meaning the element
needs changing. After changing the air element, press the dust
indicator button to reset the indicator.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 47
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DCA-125SSJU SERIES — MAINTENANCE
Air Removal
Flushing Out Radiator and Replacing Coolant
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.
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.
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.
z
z
Check hoses for softening and kinks. Check clamps for
signs of leakage.
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.
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.
z
z
z
Tighten both cocks and replace the overflow tank.
Replace with coolant (Table 12 for correct mixture).
Close radiator cap tightly.
Check Oil Level
CAUTION:
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.
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot!
will damage radiator.
Replacing Oil Filter
Generator Storage
Detach the oil filter by loosening center bolt and remove
the element together with the filter body.
For longe term storage of the generator the following is
recommended:
Apply a film of oil to the gasket for the cartridge.
z
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Install the filter body together with the element and fix
them by tightening the center bolt.
z
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
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.
z
z
z
z
z
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Replacing Fuel Filter
Make sure engine coolant is at proper level.
Replace the fuel filter cartridge with new one every 400
hours or so.
If generator is mounted on a trailer, jack trailer up and
place on block so tires do touch the ground or remove
tires.
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.
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DCA-125SSJU SERIES — MAINTENANCE
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.
Jacket Water Heater and Internal Battery Charger 120
VAC Input Receptacles (OPTIONAL)
This generator is equipped with two 120VAC, 20 amp input
receptacles located on the output terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
To ensure adequate starting
capability, always have power
applied to the generator's
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).
NOTE
internal battery charger.
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
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.
Figure 75. Battery Charger &
Jacket Water Heater Power Connections
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 49
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DCA-125SSJU SERIES —TRAILER BRAKES MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 76) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the perio
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
star wheel of the adjuster assembly to expand the brake
shoes.
Figure 76. Hydraulic Brake Components
Actuator
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the surge or push of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
Periodically check and test the surge “actuator ” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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DCA-125SSJU SERIES —TRAILER MAINTENANCE
Suspension
Tires/Wheels/Lug Nuts
The leaf suspension springs and associated components
(Figure 77) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
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
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Table 17. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
TABLE 16. TIRE WEAR TROUBLESHOOTING
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
SOLUTION
CAUSE
WEAR PATTERN
Adjust pressure to
particular load per tire
manufacturer.
Over Inflation.
Center Wear
Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.
Under Inflation.
Edge Wear
Side Wear
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
Loss of camber
or overloading.
SPRING EYE BOLT
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Check bearing adjustment
and balance tires.
Wheel lockup &
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Flat Spots
CAUTION:
ALWAYS wear safety glasses when removing
or installing force fitted parts.Failure to comply
may result in serious injury.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 51
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DCA-125SSJU SERIES —TRAILER MAINTENANCE
Lug NutTorque 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.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 78. Wheel Lug Nuts Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
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DCA-125SSJU SERIES —TRAILERWIRING DIAGRAM
Figure 79. Trailer/Towing Vehicle Wiring Diagram
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 53
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DCA-125SSJU SERIES — GENERATORWIRING DIAGRAM
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DCA-125SSJU SERIES — ENGINEWIRING DIAGRAM (IGNITION SWITCH)
Figure 81. Engine Wiring Diagram(Ignition Switch)
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DCA-125SSJU SERIES — ENGINEWIRING DIAGRAM (ENGINE CONTROLLER)
Figure 82. Engine Wiring Diagram (Engine Controller)
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NOTE PAGE
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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 EngineTroubleshooting (Table 19).
If the problem cannot be remedied, consult our company's business office or service plant.
TABLE 19. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Bleed system.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of
fuel or engine oil at low
temperature?
Use the specified fuel or engine oil.
Use the specified fuel.
Tighten nut.
Fuel with low cetane number?
Fuel leak due to loose injection
pipe retaining nut?
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Engine does not start.
Replace.
Injection nozzle clogged?
Injection pump malfunctioning?
Clean injection nozzle.
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Improper valve timing?
Piston ring and liner worn?
Excessive valve clearance?
Starter malfunctioning?
Wiring disconnected?
Correct or replace timing gear.
Replace.
Adjust.
Repair or replace.
Connect wiring.
Starter does not run.
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DCA-125SSJU SERIES —TROUBLESHOOTING (ENGINE)
TABLE 19. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Repair or replace.
Adjust.
Injection pump malfunctioning?
Engine revolution is not smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Clean.
Repair.
Reduce to the specified level.
Repair or replace.
Piston ring and liner worn or
stuck?
Either white or blue exhaust gas
is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray
exhaust gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts seem to
be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak?
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 59
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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.
TABLE 20. GENERATOR TROUBLESHOOTING
SYMPTOM
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Low Voltage Output
Turn engine throttle lever to "High".
Check wiring and repair.
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
PAGE 60 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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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 MPECTroubleshooting (Table 21).If the problem cannot be remedied,
consult our company's business office or service plant.
TABLE 21. ENGINE CONTROLLER TROUBLESHOOTING
Sympton
Possible Cause
Solution
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in Controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light
is on.
Inspect/repair wire.
Fill coolant level.
Low coolant level?
Low coolant level light
is on.
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Clean/repair radiator grill.
Close doors.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through radiator?
Doors open?
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
High coolant
temperture light is on.
Generator being overloaded?
Thermostat failure?
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
Controller needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
Engine Controller needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust RPM.
Adjust governor actuator.
Adjust governor controller.
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU light(s) or
on.
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 61
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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
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)
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DCA-125SSJU SERIES — SUGGESTED SPARE PARTS
DCA-125SSJU & DCA-125SSJU2
W/JOHN DEERE 6080TF250 DIESEL ENGINE
1TO 3 UNITS
Qty.
1
1
1
1
P/N
Description
Remarks
0601820671
0601840073
0601840121
47230107
AUTOMATIC VOLTAGE REGULATOR
RHEOSTAT VOLTAGE REGULATOR
KNOB, RHEOSTAT
KNOB, SELECTOR SWITCH
1
1
1
1
5
5
5
3
1
1
1
1
M3310500003
M3310500403
M3310500103
M3310500503
0602041290
0602042590
0602046377
0602042420
0602122272
0602123261
0601810245
R1234145
RADIATOR HOSE, UPPER .......................S/N 7500001TO7500307
RADIATOR HOSE, UPPER .......................S/N 7500307~
RADIATOR HOSE, LOWER .......................S/N 7500001TO7500307
RADIATOR HOSE, LOWER .......................S/N 7500307~
OIL FILTER
FUEL FILTER
AIR ELEMENT
FUEL FILTER, FUEL TANK
UNIT, OIL PRESSURE
UNIT, WATER TEMPERATURE
BULB, ALARM LAMP
FAN BELT
1
1
1
0602122281
0602100056
AR51481
OIL SHUTDOWN SWITCH ........................ S/N 7500001TO7500507
STARTER SWITCH
KEY, STARTER SWITCH
1
1
1
M9310000103
M1483600204
ECU9988NJD
ENCLOSURE CAP
ENCLOSURE CAP CHAIN ASSEMBLY
CONTROLLER ECU
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this book.
NOTE
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 63
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DCA-125SSJU SERIES — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
PAGE 64 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — NAMEPLATE AND DECALS
NAMEPLATE AND DECALS
NO.
1
2
3
4
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550000703
M3550000004
M3550000102
M3550000202
M3550000212
M9500000004
M9500100004
M9500100104
M9500300004
M9500300104
M9500500004
M9500500104
M9503000004
M9503000103
M9503100004
M9503200004
M9510100004
M9510200002
M9520000004
M9520000104
M9520000204
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520200003
M9520200104
M9560100003
M3560100103
M3560100203
M3560100404
M3560100303
M3650100503
M3650100604
M0600500090
0021106015
DECAL, NOTE .....................................................1 .............. M15000020
DECAL, AUXILLIARY OUTPUT...........................1 .............. M15000070
DECAL, NOTE .....................................................1 .............. M35000000
DECAL, GENERATOR CONTROL .......................1 .............. M35000010
DECAL, ENGINE OPERATING M35000020 ........1 .............. S/N7500001TO S/N7500507
DECAL, ENGINE OPERATING M35000020 ........1 .............. S/N7500508~
DECAL, OIL DRAIN PLUG ..................................1 .............. M90000000
DECAL, WATER...................................................1 .............. M90010000
DECAL, WATER DRAIN PLUG, M90010010 .......1 .............. S/N7500001TO 7500307
DECAL, - .............................................................1 .............. M90030000
DECAL, + ............................................................1 .............. M900500000
DECAL, DIESEL FUEL .......................................1 .............. M90050000
DECAL, FUEL DRAIN PLUG ...............................1 .............. M90050010
DECAL, WARNING ..............................................1 .............. M9030000
DECAL, WATER/OIL CHECK ...............................1 .............. M90310010
DECAL, WARNING ..............................................1 .............. M90310000
DECAL, WARNING ..............................................1 .............. M90320000
DECAL, CAUTION ...............................................1 .............. M91010000
DECAL, MQ.........................................................1 .............. M91020000
DECAL, GROUND ...............................................1 .............. M92000000
DECAL, AMMETER CHANGE-OVER SW...........1 .............. M92000010
DECAL, VOLTMETER CHANGE-OVER SW........1 .............. M92000020
DECAL, WARNING ..............................................2 .............. M92010000
DECAL, CAUTION ...............................................1 .............. M92010020A
DECAL, SAFETY INSTRUCTIONS .....................1 .............. M92010030
DECAL, DANGER................................................1 .............. M92010040
DECAL, WARNING ..............................................1 .............. M92010050
DECAL, CONNECTION OF OUTPUT CABLE ....1 .............. M92020010
DECAL, OVER CURRENT RELAY ......................1 .............. M92020010
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
STRIPE, WHISPERWATT
STRIPE, MQ POWER
STRIPE
1
2
2
2
1
1
3
1
2
STRIPE
STRIPE, 125
STRIPE, 125
STRIPE
EMBLEM
MACHINE SCREW
DECAL, OPERATING PROC., M35200010 .........1 .............. S/N7500508~
DECAL, CAUTION, B15200010 ...........................2 .............. S/N7500508~
DECAL, CAUTION, C90530000 ...........................1 .............. S/N7500508~
DECAL, START CONTACT, S-4468 .....................1 .............. S/N7500508~
DECAL, FUELING PROCEDURE........................1
M3552000103
B152000103
C95053000004
9039209064
TBD
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 65
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DCA-125SSJU SERIES — GENERATOR ASSY.
GENERAT
PAGE 66 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
C0110000002
PART NAME
QTY.
1
1
1
8
REMARKS
ROTOR ASSY.
FIELD ASSY.
FAN
COUPLING DISK
BALANCING PLATE
HEX. HEAD BOLT
LOCKWASHER
SET PLATE
RECTIFIER .................................................2 ............ PT3610
SURGE ABSORBER ...................................1 ............ ERZM14JK621A
INSULATORWASHER
INSULATORWASHER
HEX. HEAD BOLT
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
2
8131070013
8131611014
8131015003
0012112035
0042612000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906312
8131340213
0845041804
8131315202
8101350013
0012110060
0042610000
031110160
1
10
10
1
1
1
4
4
1
LOCKWASHER
BALANCING WEIGHT KIT
BEARING ....................................................1 ............ 6312 DDU C3
STRATOR ASSY.
1
2
1
1
4
4
3
4
5
6
7
8
GROMMET
END BRACKET
FIELD ASSY. EXCITER
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER ..........................................4 ............ REPLACES 0041210000
9
10
11
0010112035
0040012000
031112230
HEX. HEAD BOLT
LOCKWASHER
6
6
PLAIN WASHER ..........................................6 ............ REPLACES 0041212000
12
13
14
15
8131310104
8131312204
8131331003
0105050616
COVER, BEARING
GASKET, BEARING
COVER, END BRACKET
1
1
1
HEX. HEAD BOLT .....................................10 ............ REPLACES 0017106012
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 67
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DCA-125SSJU SERIES — GENERATOR ASSY. (CONT.)
GENERATOR ASSY. (CONT.)
PAGE 68 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — GENERATOR ASSY. (CONT.)
GENERATOR ASSY. (CONT.)
NO.
16
17
18
19
20
21
21
22
23
24
25
25
26
27
27
28
29
29
30
PART NO.
PART NAME
QTY.
REMARKS
8101333003
0010106030
0040006000
952404470
COVER, END BRACKET
HEX. HEAD BOLT
LOCKWASHER
1
2
2
PLAIN WASHER ............................... 2 ......... REPLACES 0041206000
COUPLING RING
HEX. HEAD BOLT ............................ 8 ......... S/N 7500001TO 7500242
HEX. HEAD BOLT ............................ 8 ......... S/N 7500243~
LOCKWASHER ................................ 8 ......... REPLACES 0043604000
BEARING ......................................... 1 ......... 6306ZZ
HEX. HEAD BOLT
HEX. HEAD BOLT .......................... 12 ......... S/N 7500001TO 7500242
HEX. HEAD BOLT .......................... 12 ......... S/N 7500243~
LOCKWASHER .............................. 12 ......... S/N 7500001TO 7500242
COVER, FAN .................................... 1 ......... S/N 7500001TO 7500242
COVER, FAN .................................... 1 ......... S/N 7500243~
RUBBER SUSPENSION
HEX. NUT
M3163400003
0013904044
0343204150
EM923344
1
0070506306
0012810030
0012810030
0010310035
0042510000
8131332003
8131332014
0605000063
00300165000
0040016000
020106050
12
2
2
2
LOCKWASHER
NUT .................................................. 1 ......... REPLACES 0600815000
...................................................................... S/N 7500004~
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 69
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DCA-125SSJU SERIES — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 70 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
1
1
1
2
3
4
5
6
7
7
8
PART NO.
PART NAME
QTY.
REMARKS
M3213000102
M3213000112
M3213000122
M3213000132
0601808813
0021006080
0601823863
0021304015
0601820671
0027105010
0027105015
0601806118
011808015
CONTROL BOX .................................................. 1 ........... S/N 7500001TO 7500048
CONTROL BOX .................................................. 1 ........... S/N 7500049TO 7500222
CONTROL BOX .................................................. 1 ........... S/N 7500223TO 7500507
CONTROL BOX .................................................. 1 ........... S/N 7500508~
CIRCUIT BREAKER ........................................... 1 ........... LAF363001021 3P 300A
MACHINE SCREW
RELAY UNIT....................................................... 2 ........... MSA9013A
MACHINE SCREW ............................................. 4 ........... REPLACES 0027104015
4
AUTOMATICVOLTAGE REGULATOR ................. 1 ........... NTA5A2DB
MACHINE SCREW ............................................. 4 ........... S/N 7500001TO 7500222
MACHINE SCREW ............................................. 4 ........... S/N 7500223~
CURRENT TRANSFORMER ............................. 3 ........... 814943 200/5A
MACHINE SCREW ............................................. 6 ........... REPLACES 0027106015
OVER CURRENT RELAY ................................... 1 ........... LR2D1308
9
10
11
12
13
13
14
15
15
16
17
17A
18
19
20
21
22
23
24
25
26
26
27
28
28
0601820845
0601820846
M1260600004
0021304015
0030004000
0027105020
M3213500003
M3213500013
011106015
OVER CURRENT RELAY ................................... 1 ........... LA7D1064
FITTING BRACKET ........................................... 1 ........... S/N 7500001TO 7500222
MACHINE SCREW ............................................. 2 ........... REPLACES 0027104015
HEX. NUT ........................................................... 2 ........... REPLACES 0207004000
MACHINE SCREW
4
CONTROL BOX COVER..................................... 1 ........... S/N 7500001TO 7500048
CONTROL BOX COVER..................................... 1 ........... S/N 7500049~
HEX. HEAD BOLT .............................................. 4 ........... REPLACES 0016906015
SELECTOR SWITCH ......................................... 1 ........... VY125
KNOB, SELECTOR SWITCH
SPACER
SWITCH BRACKET
EDGING
SWITCH BOARD
MACHINE SCREW ............................................. 4 ........... REPLACES 0021104010
HEX. HEAD BOLT .............................................. 6 ........... REPLACES 0016906015
SWITCH COVER ................................................ 1 ........... REPLACES M3213600104
HEX. HEAD BOLT .............................................. 4 ........... REPLACES 0016906015
HEX. HEAD BOLT ............................................ 10 ........... REPLACES 0016906015
TOOTHEDWASHER
CONTROL PANEL
M3923100004
47230107
1
8
1
2
1
M3276600004
M3213600003
0330000295
M3260500004
0020004010
011106015
M3213600114
011106015
011106015
0040506000
M3223000103
0601807630
0601807641
1
1
FREQUENCY METER,264250DJDJ9 ................ 1 ........... S/N 7500001TO 7500842
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
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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)
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DCA-125SSJU SERIES — CONTROL BOX ASSY. (CONT.)
CONTROL BOX ASSY. (CONT.)
NO.
29
29
30
31
31
32
33
34
35
36
37
38
39
40
41
41
41
42
43
44
45
46
47
PART NO.
PART NAME
QTY.
REMARKS
0601808953
0601808988
0601801040
0601806813
0601806859
0601801041
0601840073
0601840121
M122310004
0027105015
0027105015
M9220100004
0080200007
0601823240
0027104020
0027105020
0027104020
0602200478
0027105040
0602202592
011808015
AC AMMETER, 260240LSLS1JCA .............1 ............ S/N 7500001TO 7500842
AC AMMETER, ACF-6 - 200A,0-400A/5A ...1 ............ S/N 7500843~
CHANGE-OVER SWITCH, AMMETER .......1 ............ SL2AS
AC VOLTMETER, 260244SJSJ1 .................1 ............ S/N 7500001TO 7500842
AC AMMETER, SCF-6 0-600V ....................1 ............ S/N 7500843~
CHANGE-OVER SWITCH, VOLTMETER ....1 ............ SL2VS
RHEOSTAT (VOLTAGE REGULATOR) .........1 ............ RA20A2SE102BJ 2W 1K OHM
KNOB
1
1
2
1
1
1
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
RECTIFER...................................................1 ............ DE4503
MACHINE SCREW ......................................1 ............ S/N 7500001TO 7500307
MACHINE SCREW ......................................1 ............ S/N 7500308TO 7500507
MACHINE SCREW ......................................1 ............ S/N 7500508~
EMERGENCY RELAY, 10701606023 ..........1 ............ S/N 7500001TO 7500507
MACHINE SCREW ......................................2 ............ S/N 7500001TO 7500507
STARTER RELAY........................................1 ............ AT141011
MACHINE SCREW ......................................2 ............ REPLACES 0027106015
RECTIFER, DE4503 ....................................1 ............ S/N 7500508~
0601823240
DYN110794000012 CONTROLLER.............................................1 ............ REPLACES 0602202599
................................................................................... S/N 7500508~
47
48
49
49
MPS6724
SPEED SENSOR, MAGNETIC PICK UP ...1 ............ REPLACES 0602120485
MACHINE SCREW ......................................4 ............ S/N 7500508~
RELAY, LY2US12VD ....................................1 ............ S/N 7500508TO 7500542
RELAY .........................................................1 ............ REPLACES 0601827656
................................................................................... S/N 7500543~
0027105015
0601823768
LY2US12VDC
49
49
PTF08AE
PYCA1
BASE, RELAY SOCKET .............................1 ............ REPLACES 0601823109
................................................................................... S/N 7500508~
CLIP ............................................................2 ............ REPLACES 0601824400
................................................................................... S/N 7500508~
50
51
52
0601823223
0027104020
M3246700304
RECTIFER...................................................1 ............ 30D4 S/N 7500508TO 7500542
MACHINE SCREW ......................................2 ............ S/N 7500508~
WIRE HARNESS, GENERATOR
1
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 73
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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)
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DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
M3923200004
0602041290
0602042590
0602014297
RE502668
ENGINE .............................................. 1 .................JOHN DEERE 6068TF
ELEMENT, OIL FILTER ...................... 1 .................RE59754A
ELEMENT, FUEL FILTER .................. 1 .................RE62418
ELECTRIC HEATER........................... 1 .................RE29658
ELECTRIC HEATER ASSY. .....................................S/N 7500263-
BLOWER FAN .................................... 1 .................422198
1-1
1-2
1-3
1-3
2
0602060010
0602061000
0012110090
0012110095
030210250
3
FAN SPACER ...................................... 1 .................R81911
HEX. HEAD BOLT ............................... 4 .................S/N 7500001 TO 7500003
HEX. HEAD BOLT
LOCK WASHER ................................. 4 .................REPLACES 0042510000
ENGINE FOOT
HEX HEAD BOLT ............................... 6 .................REPLACES 0010312030
4
4
4
5
6
M2303200303
0131151240
0040012000
0605000060
0030012000
0040012000
0602011988
0602012723
0602012747
0602011067
0602011066
0199101200
0602010795
0013006008
0043106000
M3310200204
M3310200404
0013006008
0043006000
0043106000
011008020
2
7
8
LOCK WASHER
RUBBER SUSPENSION
HEX. NUT
6
2
2
2
9
10
11
12
12
12
12-1
12-1
12-2
13
14
15
16
17
18
19
20
21
22
23
23
24
24
25
26
27
28
29
30
31
32
33
34
34
35
36
37
38
39
40
41
42
43
LOCK WASHER
RADIATOR, RE52824 ........................ 1 .................S/N 7500001 TO 7500003
RADIATOR, C2810060000 ................ 1 .................S/N 7500308 TO 7500952
RADIATOR, C281-009-003 ................ 1 .................S/N 7500953
CAP ..................................................... 1 .................S/N 7500001 TO 7500307
CAP ..................................................... 1 .................S/N 7500308~
HOSE .................................................. 1 .................S/N 7500308~
FAN COVER, C2810044210 .............. 1 .................S/N 7500001 TO 7500307
HEX. HEAD BOLT ............................... 8 .................S/N 7500001 TO 7500307
PLAIN WASHER ................................. 8 .................S/N 7500001 TO 7500307
RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 7500307
RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 7500307
S/N 7500001 TO 7500307 ................. 8 .................S/N 7500001 TO 7500307
LOCK WASHER ................................. 8 .................S/N 7500001 TO 7500307
PLAIN WASHER ................................. 8 .................S/N 7500001 TO 7500307
HEX HEAD BOLT ............................... 8 .................REPLACES 001690820
PLUG .................................................. 1 .................S/N 7500001 TO 7500307
RADIATOR HOSE, UPPER ................ 1 .................S/N 7500001 TO 7500307
RADIATOR HOSE, UPPER ................ 1 .................S/N 7500308~
0468102000
M3310500003
M3310500403
M3310500103
M3310500503
0605515148
0605515147
0605512190
M2320300103
M9200200004
0150000018
0016906020
0191300580
0605515189
0602046258
0602046377
0602040650
0603306385
0602040596
011008020
RADIATOR HOSE, LOWER............... 1 .................S/N 7500001 TO 7500307
RADIATOR HOSE, LOWER............... 1 .................S/N 7500308~
HOSE BAND
HOSE BAND
HOSE JOINT
2
2
1
DRAIN JOINT ..................................... 1 .................S/N 7500001 TO 7500307
DRAIN BOLT....................................... 1 .................S/N 7500001 TO 7500307
O RING ............................................... 1 .................S/N 7500001 TO 7500307
HEX HEAD BOLT ............................... 2 .................S/N 7500001 TO 7500307
DRAIN HOSE ...................................... 1 .................S/N 7500001 TO 7500307
HOSE BAND ....................................... 2 .................S/N 7500001 TO 7500307
AIR CLEANER .................................... 1 .................FRG100297
ELEMENT, AIR CLEANER ................. 1 .................P778214
INDICATOR, AIR CLEANER .............. 1 .................RBX002252
NIPPLE................................................ 1 .................S/N 7500001 TO 7500004
BAND, AIR CLEANER........................ 1 .................P004076
HEX. HEAD BOLT ............................... 4 .................REPLACES 0016908020
HEX, NUT ........................................... 4 .................REPLACES 0207008000
020108060
M337310003
0605515146
0605515200
0602022563
HOSE, AIR CLEANER
1
HOSE BAND ....................................... 1 .................5035
HOSE BAND ....................................... 1 .................5072
ADAPTER
1
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 75
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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)
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DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY. (CONT.)
ENGINE AND RADIATOR ASSY. (CONT.)
NO.
44
45
46
47
48
49
49
50
51
52
53
54
55
56
56
57
57
58
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
PART NO.
PART NAME
QTY.
REMARKS
0602021165
0602022561
0602022562
0602022792
0602021070
0602021573
0269200406
M9300000203
06020100900
M3316100104
0110080020
0193601080
M2260600024
0602202597
0602202592
0017106015
011808015
O-RING .......................................... 1 ........... S/N 7500001TO 7500307
90o ELBOW .................................... 1 ........... 3398210-10+
UNION, 10WTXWLNS.................... 1 ........... S/N 7500001TO 7500307
SWIVEL, 306821010 ...................... 1 ........... S/N 7500001TO 7500307
CAP ............................................... 1 ........... 10FNTXS
DRAIN HOSE................................. 1 ........... 83610 S/N 7500001TO 7500307
DRAIN HOSE................................. 1 ........... 83610 S/N 7500263~
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HEX.HEAD BOLT .......................... 2 ........... REPLACES 0016908020
HOSE
1
1
1
1
1
RELAY BRACKET
RELAY, AL64309 ............................ 1 ........... S/N 7500001 TO 7500262
RELAY, AT141011 .......................... 1 ........... S/N 7500263~
HEX. HEAD BOLT.......................... 1 ........... S/N 7500001 TO 7500262
MACHINE SCREW ........................ 2 ........... REPL. 0027106015 S/N 7500263~
RADIATOR COVER ........................ 1 ........... S/N 7500001 TO 7500307
RADIATOR COVER ........................ 1 ........... S/N 7500508~
HEX. HEAD BOLT.......................... 4 ........... REPLACES 0016908020
LOCKWASHER ............................. 8 ........... S/N 7500001 TO 7500307
HEX. HEAD BOLT.......................... 1 ........... REPLACES 0016908020
OIL SWITCH .................................. 1 ........... 1718939011
M3313100004
M3313100204
0110080020
0043006000
0110080020
0602122281
0602123282
M9200100404
M9200100704
0605511395
DYNC700250000012
M3356200004
0016910015
0016906020
0207006000
0603306590
0603300285
0603306395
0602011491
WATER SWITCH ............................ 1 ........... 1518183041
ADAPTER
1
ADAPTER ...................................... 1 ........... S/N 7500004~
VALVE, XV500P8 .......................... 1 ........... S/N 7500508~
ACTUATOR .................................... 1 ........... REPL. 0602150093 S/N 7500508~
STOPPER BRACKET .................... 1 ........... S/N 7500508~
HEX. HEAD BOLT.......................... 1 ........... REPL. 0017110020 S/N 7500508~
HEX. HEAD BOLT.......................... 1 ........... S/N 7500508~
HEX. NUT ...................................... 1 ........... S/N 7500508~
CONNECTOR, 10WFTXS .............. 1 ........... S/N 7500508~
ROCK UNIT, 10WLN ...................... 1 ........... S/N 7500508~
HOSE JOINT, 30182810 ................ 1 ........... S/N 7500508~
FAN BELT
1
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 77
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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)
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DCA-125SSJU SERIES — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
M1354300304
M9320000004
0036003000
0605804150
0041208000
M1354200004
0207008000
0030008000
0605010550
M3354300104
0602180106
0030008000
0602180107
0036508000
0207006000
0041206000
AR51481
0602100056
0602100028
0602100029
0601831594
0601831585
0601831584
0601831588
0602120096
0602122093
0602122272
0602123092
0602123261
0602121080
0602125090
0602103092
0601810245
0601810141
0601831330
ECU9988NJD
0027104035
0030000400
0601831340
0600500091
0601831395
M3357200002
M3357200012
M3359200302
SLIDE LEVER .............................................1 ............ S/N 7500001TO 7500507
KNOB ..........................................................1 ............ S/N 7500001TO 7500507
HEX. NUT ....................................................1 ............ S/N 7500001TO 7500507
SPRING.......................................................1 ............ S/N 7500001TO 7500507
PLAIN WASHER ..........................................2 ............ S/N 7500001TO 7500507
BRACKET ...................................................1 ............ S/N 7500001TO 7500507
HEX NUT .....................................................1 ............ S/N 7500001TO 7500507
HEX NUT .....................................................1 ............ S/N 7500001TO 7500507
SNAP PIN ...................................................1 ............ S/N 7500001TO 7500507
GOVERNOR ROD .......................................1 ............ S/N 7500001TO 7500507
BALL JOINT, LHSA8DE161.........................1 ............ S/N 7500001TO 7500507
HEX NUT .....................................................1 ............ S/N 7500001TO 7500507
BALL JOINT, LHSA8DLE161 .......................1 ............ S/N 7500001TO 7500507
HEX NUT .....................................................1 ............ S/N 7500001TO 7500507
HEX NUT .....................................................2 ............ S/N 7500001TO 7500507
PLAIN WASHER ..........................................2 ............ S/N 7500001TO 7500507
KEY, STARTER SWITCH ............................1 ............ S/N 7500001TO 7500507
STARTER SWITCH, AR58126.....................1 ............ S/N 7500001TO 7500507
SET NUT, R44342 .......................................1 ............ S/N 7500001TO 7500507
SET WASHER, A4827R ..............................1 ............ S/N 7500001TO 7500507
COLD STARTER BUTTON, R39554 ............1 ............ S/N 7500001TO 7500342
COLD STARTER BUTTON ..........................1 ............ S/N 7500343~
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16A
16
16
16
17
17
17
17
18
19
20
21
22
23
24
25
25
26
27
28
29
29
30
30
31
32
32
32
CAP, T55585 ................................................1 ............ S/N 7500001TO 7500342
CAP, 44053 ..................................................1 ............ S/N 7500343~
TACHOMETER ............................................1 ............ 103678
OIL PRESSURE GAUGE ............................1 ............ 100174
UNIT, OIL PRESSURE
1
WATER TEMPERATURE GAUGE ...............1 ............ 100182
UNIT, WATER TEMPERATURE ...................1 ............ 0202500
CHARGING AMMETER ..............................1 ............ 100158
FUEL GAUGE..............................................1 ............ 100176
ALARM LAMP, PL05....................................2 ............ S/N 7500001TO 7500507
BULB, E10T10 DC18V ................................2 ............ S/N 7500001TO 7500507
PANEL LIGHT ..............................................1 ............ 9826800370
SWITCH, PANEL LIGHT..............................1 ............ 900001
ENGINE CONTROLLER ..............................1 ............ REPLACES 0602202545
MACHINE SCREW ......................................2 ............ S/N 7500508~
HEX. NUT ....................................................2 ............ REPL. 0207004000 S/N 7500508~
SWITCH, 7562K4 ........................................1 ............ S/N 7500508~
NAME PLATE ..............................................1 ............ S/N 7500508~
SWITCH, 7302K36 ......................................1 ............ S/N 7500508~
WIRE HARNESS, ENGINE .........................1 ............ S/N 7500001TO 7500262
WIRE HARNESS, ENGINE .........................1 ............ S/N7500263TO 7500507
WIRE HARNESS, ENGINE .........................1 ............ S/N7500508~
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 79
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DCA-125SSJU SERIES — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 80 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
1
PART NO.
PART NAME
QTY.
1
REMARKS
M3230700003
M9220100304
M9220100404
0039316000
0040016000
0041416000
0012108035
M3236100303
M3236100313
M3238100103
M3236100104
0605010040
0027103010
0207003000
0041203000
0027103010
0207003000
011206020
0016906015
M2236400004
M3236400004
M2236300004
M3236300004
011206020
0601808803
0601808804
M1260700304
0222100150
011206020
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT .................................... 5 .............. REPLACES 0016908035
TERMINAL COVER .................................. 1 .............. S/N 7500001TO 7500307
TERMINAL COVER .................................. 1 .............. S/N7500308TO S/N7500507
TERMINAL COVER .................................. 1 .............. S/N7500508~
2
5
3
5
4
10
15
20
5
6
7
8
8
8
9
OUTPUTWINDOW
HINGE
MACHINE SCREW
1
2
4
10
11
11
11
12
12
13
14
15
15
16
16
17
18
19
20
20-1
21
22
23
24
24
25
25
26
27
28
29
30
31
32
32
33
HEX. NUT ................................................. 4 .............. REPLACES 0030003000
PLAIN WASHER
MACHINE SCREW
4
4
HEX. NUT ................................................. 4 .............. REPLACES 0030003000
HEX. HEAD BOLT .................................... 2 .............. REPLACES 0016906020
HEX. HEAD BOLT
CABLE OUTLET COVER ......................... 1 .............. S/N 7500001TO 7500034
CABLE OUTLET COVER ......................... 1 .............. S/N 7500035~
SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500001TO 7500034
SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500035~
HEX. HEAD BOLT .................................... 6 .............. REPLACES 0016906020
CIRCUIT BREAKER ................................. 2 .............. Q0U 120B 1P 20A
CIRCUIT BREAKER ................................. 3 .............. Q0U 250B 2P 50A
4
BREAKER FITTING COVER
CUSHION RUBBER
1
1
HEX. HEAD BOLT .................................... 2 .............. REPLACES 0016906020
RECEPTACLE, GF530EM 125V 20AX2 ... 2 .............. REPLACES 0601812598
RECEPTACLE, CS6369 250V 50A ........... 3 .............. REPLACES 0601812538
MACHINE SCREW ................................. 10 .............. REPLACES 0027104015
HEX. NUT ............................................... 10 .............. REPLACES 0207004000
TERMINAL COVER .................................. 1 .............. S/N 7500001TO 7500034
TERMINAL COVER .................................. 1 .............. S/N 7500035~
0601812597
0601811034
0021304015
0030004000
M3236100203
M3236100213
012212045
HEX. HEAD BOLT .................................... 2 .............. REPLACES 0010112045
031112230
PLAIN WASHER
STAY RUBBER
NUT
2
2
2
M9310200004
0030012000
M2354200004
0016906015
M3455600004
0603306775
0021304015
SUPPORTER, GOVERNOR ROD ............ 1 .............. S/N 7500001TO 7500507
HEX. HEAD BOLT .................................... 2 .............. S/N 7500001TO 7500507
PLUG ........................................................ 2 .............. S/N 7500508~
PLUG ........................................................ 2 .............. S/N 7500508~
MACHINE SCREW ................................... 4 .............. REPLACES 0027104015
................................................................................... S/N 7500508~
34
35
0601815194
0021304015
TERMINAL, 6041GP02 ............................ 1 .............. S/N 7500508~
MACHINE SCREW ................................... 2 .............. REPL. 0027104015 S/N 7500508~
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 81
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DCA-125SSJU SERIES — BATTERY ASSY.
BATTERY ASSY.
PAGE 82 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
7
PART NO.
PART NAME
QTY.
REMARKS
0602220196
M9310500404
M9103000504
0602220921
0040006000
M3346900004
M3346900104
BATTERY ....................................................1 ............ 4D-2
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
LOCKWASHER
BATTERY CABLE
BATTERY CABLE
1
1
2
2
1
1
8
9
9
10
10
CABLE.........................................................1 ............ MAKE LOCALLY
0017112025
0040512000
0017110020
0040510000
HEX. HEAD BOLT
TOOTHEDWASHER
HEX. HEAD BOLT
TOOTHEDWASHER
1
1
1
1
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 83
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DCA-125SSJU SERIES — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 84 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
PART NO.
M3330100002
0602300167
PART NAME
QTY.
REMARKS
MUFFLER....................................................1 ............ S/N 7500001TO 7500072
MUFFLER....................................................1 ............ S/N 7500073~
1
2
3
4
10 0602326061 U BOLT SET 1
89547K
012210025
HEX. HEAD BOLT .......................................4 ............ REPLACES 0016910025
EXHAUST PIPE
CLAMP
GASKET
M3333000303
0602325066
M3333200004
014210040
1
1
1
5
6
HEX. HEAD BOLT .......................................4 ............ REPLACES 0017110040
7
8
9
10
M33330400304
M3330400403
011008020
COVER
BRACKET
1
1
HEX. HEAD BOLT .......................................4 ............ REPLACES 0016908020
U-BOLT SET................................................1 ............ 89547K
0602326061
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 85
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DCA-125SSJU SERIES — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 86 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
1-1
2
3
4
5
5
5
6
PART NO.
PART NAME
QTY.
REMARKS
M3363000202
0605505070
M3363200204
M9310500104
0016908020
037908000
FUEL TANK
1
1
2
4
2
CAP, FUEL TANK
TANK BAND
SUPPORTERsheet
HEX. HEAD BOLT
HEX NUT .....................................................2 ............ S/N 7500001TO 7500034
HEX NUT .....................................................2 ............ S/N 7500035~
PLAIN WASHER ..........................................2 ............ S/N 7500001TO 7500034
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
O RING ........................................................1 ............ AP18
HEX. HEAD BOLT
DRAIN HOSE
HOSE BAND ...............................................2 ............ 5008
FUEL FILTER ..............................................1 ............ PTG15P
LEAK-OFF LINE ..........................................1 ............ RE67050
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
0207308000
0041208000
0222100660
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
0602042420
0602042601
0191300450
0191301802
0191302200
0605515189
0605515109
0602220911
2
1
1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2
1
1
1
1
HOSE BAND ...............................................1 ............ 91004
HOSE BAND ...............................................5 ............ RS8010
CLAMP ........................................................1 ............ RCT2010
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 87
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DCA-125SSJU SERIES — ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
6 -CATERPILLARYELLOW
7 -CATO GOLD
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 88 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
1
1
2
3
4
4
4
PART NO.
PART NAME
QTY.
REMARKS
M3413000102
M3413000112
M3413000122
M1413400004
012210025
BASE ................................................ 1 ........... S/N 7500001TO 7500307
BASE ................................................ 1 ........... S/N 7500308TO S/N7500507
BASE ................................................ 1 ........... S/N7500508~
UNDER COVER
1
HEX. HEAD BOLT ............................. 2 ........... REPLACES 0016910025
FRONT FRAME................................. 1 ........... S/N 7500001 TO S/N 7500307
FRONT FRAME................................. 1 ........... S/N7500308~
ACOUSTIC SHEET ........................... 1 ........... S/N7500283TO S/N7500307
ACOUSTIC SHEET ........................... 1 ........... S/N7500308~
M3423000302
M3423000602
M3493100203
M3493100503
012210025
4
5
HEX. HEAD BOLT ............................. 6 ........... REPLACES 0016910025
6
6
7
M3423200104
M3493100304
011008020
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT ........................... 14 ........... REPLACES 0016908020
1
1
8
8
9
9
9
9
10
10
10
11
12
13
13
14
15
16
16
17
18
18
M3433000102
M3493200004
0010114040
0030014000
0040014000
031114260
M3443000202
M3443000212
M3493300204
012210025
M3443300203
M3443300303
M3493300303
0207006000
011008020
M3443200103
M3443200113
M3443600104
0037906000
020106050
CENTER FRAME
ACOUSTIC SHEET
HEX. HEAD BOLT
HEX. NUT
1
1
12
12
24
LOCKWASHER
PLAIN WASHER .............................. 24 ........... REPLACES 0041214000
REAR FRAME ................................... 1 ........... S/N 7500001 TO S/N 7500507
REAR FRAME ................................... 1 ........... S/N7500508~
ACOUSTIC SHEET
HEX. HEAD BOLT ............................. 4 ........... REPLACES 0016910025
1
REAR COVER
1
1
1
DUCT, REAR COVER
ACOUSTIC SHEET
HEX. NUT
HEX. HEAD BOLT ........................... 10 ........... REPLACES 0016908020
REAR DOOR ..................................... 1 ........... S/N 7500001 TO S/N 7500148
REAR DOOR ..................................... 1 ........... S/N 7500149~
WINDOW PLATE ............................... 1
HEX. NUT ........................................ 10 ........... S/N 7500001 TO S/N 7500034
HEX. NUT ........................................ 10 ........... REPLACES 0207306000
......................................................................... S/N 7500035~
PLAIN WASHER .............................. 10 ........... S/N 7500035~
PLAIN WASHER .............................. 20 ........... S/N 7500001 TO S/N 7500034
DOOR HANDLE ASSY.
MACHINE SCREW ............................ 4 ........... REPLACES 0021806015
HEX. NUT .......................................... 4 ........... REPLACES 0030006000
HINGE
WASHER
12
18
18
19
20
20
21
22
23
24
0041206000
0041206000
B9114000002
0027106016
020106050
M9110100204
M9116100004
011008020
1
2
2
HEX. HEAD BOLT ............................. 3 ........... REPLACES 0016908020
BLIND PLUG
M9310000004
2
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 89
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DCA-125SSJU SERIES — ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
ADD TH
WHEN
COLOR
5 -BLACK
1-ORANGE
6 -CATERPILLARYELLOW
7 -CATO GOLD
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 90 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
NO.
25
25
26
26
27
28
29
30
31
31
31
31
31
31
32
33
34
34
35
35
36
36
37
37
38
38
39
39
40
40
41
42
43
43
44
45
46
47
48
49
50
51
52
53
53
PART NO.
PART NAME
QTY.
REMARKS
M3463100203
M3493500203
M3463200102
M3493500303
M3463500104
011008020
ROOF PANEL
1
1
1
1
1
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
OVER COVER, FRONT FRAME
HEX. HEAD BOLT ....................................37 ............. REPLACES 0016908020
ENCLOSURE CAP
CHAIN ASSY.
SPLASHER PANEL ................................... 1 ............. S/N 7500001TO S/N 7500034
SPLASHER PANEL ................................... 1 ............. S/N 7500035TO S/N7500307
SPLASHER PANEL ................................... 1 ............. S/N 7500308TO S/N7500507
SPLASHER PANEL ................................... 1 ............. S/N7500508~
ACOUSTIC SHEET
ACOUSTIC SHEET
HEX. HEAD BOLT ..................................... 4 ............. REPLACES 0016908055
HEX. HEAD BOLT ..................................... 2 ............. REPLACES 0016910025
SIDE DOOR
ACOUSTIC KIT A.S. FRONT DOOR (L)
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR (L)
M9310000103
M1483600204
M3453200102
M3453200102
M3453200122
M3453200132
M3493401304
M3493401314
011208060
1
1
1 ............. S/N 7500001TO S/N 7500034
1 ............. S/N 7500035~
012210025
M3453000703
M3493400704
M3453000603
M3453400804
M3453000503
M3493401004
M3453000403
M3493401104
M3453300303
M3493400904
M3453300503
M3493401404
M3453300203
M3493401204
0207006000
B9114000002
0027106016
020106050
M9110100204
M9110100304
M9116100004
011008020
0601850097
0027208025
0845031504
M3453700004
0016906015
016908020
1
1
1
1
1
1
1
1
1
1
1
ACOUSTIC SHEET (L)
SIDE DOOR (R)
ACOUSTIC KIT A.S. REAR DOOR (R)
DUCT (L)
ACOUSTIC KIT A.S. FRONT DUCT (L)
DUCT (R FRONT)
ACOUSTIC KIT A.S. FRONT DOOR DUCT1
DUCT (R)
ACOUSTIC KIT A.S. REAR DOOR DUCT 1
HEX. NUT 25
DOOR HANDLE ASSY. ............................. 4 ............. REPLACES M9113000002
MACHINE SCREW ...................................16 ............. REPLACES 0021806015
HEX. NUT .................................................16 ............. REPLACES 0030006000
HINGE (L)
HINGE (R)
WASHER
1
4
4
8
HEX. HEAD BOLT ..................................... 9 ............. REPLACES 0016908020
DOOR STOPPER
MACHINE SCREW
8
8
BLIND PLUG ............................................. 8 ............. REPLACES M9310000004
DOOR BRACKET
HEX. HEAD BOLT
HEX. HEAD BOLT
TOOTHEDWASHER
1
4
1
1
0040508000
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 91
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DCA-125SSJU SERIES — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 92 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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DCA-125SSJU SERIES — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
3
1
2
4
4
2
4
1
2
1
1
1
1
1
1
1
REMARKS
0228900890
0229200810
0228901020
0228900990
0228900955
0228900470
0228900470
0229201040
0228800970
0228800590
0228800630
0228100665
0228100300
0228100370
0228100280
0228100365
0228100070
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
9
10
11
12
13
14
15
16
17
1
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 93
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Effective: October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5. Parts must be in new and resalable
condition,intheoriginalMultiquippack-
age (if any), and with Multiquip part
numbersclearlymarked.
Rebatesforpricedeclinesandaddedcharges
for price increases will not be made for stock
onhandatthetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
Multiquip reserves the right to quote and sell
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifest has been obtained from the carrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
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
priortothereturndate.
A$35.00surchargewillbeaddedtotheinvoice
forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremadein
connectionwiththesaleofpartsortradeacces-
soriesnorastoanyenginenotmanufactured
byMultiquip.Suchwarrantiesmadeinconnec-
tion with the sale of new, complete units are
madeexclusivelybyastatementofwarranty
packagedwithsuchunits, andMultiquipnei-
ther assumes not authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification,pending
instructions. If a reply is not received
within five days, the material will be
returnedtothesenderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. Incaseswhereanitemisaccepted,for
which the original purchase document
cannotbedetermined,thepricewillbe
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cific date and all orders received on or after
that date will be billed at the revised price.
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 94 — DCA-125SSJU SERIES (STANDARD) — PARTS AND OPERATION MANUAL — REV. #4 (06/03/03)
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NOTE PAGE
DCA-125SSJU SERIES (STANDARD)— PARTS AND OPERATION MANUAL— REV. #4 (06/03/03) — PAGE 95
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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: 800-672-7877 or 310-637-3284
SERVICE DEPARTMENT
800-421-1244
FAX: 310- 537-4259
TECHNICAL ASSISTANCE
800-478-1244
FAX: 310- 631-5032
WARRANTY DEPARTMENT
888-661-4279, or 310-661-4279
FAX: 310- 537-1173
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
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