MQ POWER DCA-125SSJU DCA-125SSJU2 PORTABLE · PDF fileCoolant Capacity 10.3 gal. ......

MULTIQUIP INC..... PARTS DEPARTMENT:18910 WILMINGTON AVE. 800-427-1244CARSON, CALIFORNIA 90746 FAX: 800-672-7877310-537-3700 SERVICE DEPARTMENT:800-421-1244 800-835-2551FAX: 310-537-3927 FAX: 310-638-8046E-mail:[email protected] www:multiquip.com

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MQ POWERDCA-125SSJUDCA-125SSJU2

PORTABLEGENERATOR

(STANDARD)

OPERATION AND PARTS MANUAL

Revision #4 (06/03/03)

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

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

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIALNUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT800-427-1244 or 310-537-3700FAX: 800-672-7877 or 310-637-3284

SERVICE DEPARTMENT800-421-1244FAX: 310- 537-4259

TECHNICAL ASSISTANCE800-478-1244FAX: 310- 631-5032

WARRANTY DEPARTMENT888-661-4279, or 310-661-4279FAX: 310- 537-1173


TABLE OF CONTENTS

Specification and partnumber are subject tochange without notice.

NOTE

COMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRACOMPONENT DRAWINGSWINGSWINGSWINGSWINGSName Plate And Decals ............................................ 64-65Generator Assembly .................................................. 66-69Control Box Assembly ............................................... 70-73Engine & Radiator Assembly ..................................... 74-77Engine Operating Panel Assembly ............................ 78-79Output Terminal Assembly ......................................... 80-81Battery Assembly ...................................................... 82-83Muffler Assembly ...................................................... 84-85Fuel Tank Assembly .................................................. 86-87Enclosure Assembly ................................................. 88-91Rubber Seal Assembly .............................................. 92-93

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

DCA-125SSJU &DCA-125SSJU &DCA-125SSJU &DCA-125SSJU &DCA-125SSJU &DCA-125SSJU2DCA-125SSJU2DCA-125SSJU2DCA-125SSJU2DCA-125SSJU2AC GENERAAC GENERAAC GENERAAC GENERAAC GENERATORTORTORTORTORHere's How To Get Help .................................................... 3Table Of Contents ............................................................. 4Parts Ordering Procedures ............................................... 5Specifications ................................................................... 6Dimensions (Top, Side, Front) ........................................... 7Safety Message Alert Symbols .................................... 8-9Rules for Safe Operation ........................................... 10-13Installation ................................................................. 14-15Towing Safety Precaution ............................................... 16Trailer Specifications ................................................. 17-19Generator Decals ....................................................... 20-21General Information ........................................................ 22Major Components ......................................................... 23Generator Control Panel ................................................. 24Engine Operating Panel (up to S/N 7500507) ................. 25Engine Operating Panel (S/N 7500508~) ................... 26-27Output Terminal Panel Familiarization ........................ 28-30Load Application ............................................................. 31Generator Outputs ..................................................... 32-33Gauge Reading ............................................................... 33Output Terminal Panel Connections ........................... 34-35Pre Setup .................................................................. 36-40Generator Start-up Procedure (Manual) ..................... 41-44Generator Start-up Procedure (Auto Mode) .................... 45Generator Shut-Down Procedure .................................... 46Maintenance .............................................................. 47-49Trailer Brakes Maintenance ............................................ 50Trailer Maintenance.................................................... 51-52Trailer Wiring Diagram ..................................................... 53Generator Wiring Diagram ............................................... 54Engine Wiring Diagram (Ignition Switch) ......................... 55Engine Wiring Diagram (w/ Controller) ............................ 56Engine Troubleshooting .............................................. 58-59Generator Troubleshooting .............................................. 60Engine Controller Troubleshooting ................................... 61Explanation of Code in Remarks Column ....................... 62Suggested Spare Parts .................................................. 63


PARTS ORDERING PROCEDURES

When ordering parts,please supply the following information:

❒❒❒❒❒ Dealer account number❒❒❒❒❒ Dealer name and address❒❒❒❒❒ Shipping address (if different than billing address)❒❒❒❒❒ Return fax number❒❒❒❒❒ Applicable model number❒❒❒❒❒ Quantity, part number and description of each part❒❒❒❒❒ Specify preferred method of shipment:

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

Here’s how to get help...Please have the model and serial number onhand when calling.

Parts Department800-427-1244 Fax: 800-672-7877310-537-3700 Fax: 310-637-3284

Mayco Parts800-306-2926 Fax: 800-672-7877310-537-3700 Fax: 310-637-3284

Service Department800-478-1244 Fax: 310-537-4259310-537-3700

MQ Power Service Department800-835-2551 Fax: 310-638-8046310-537-3700

Warranty Department800-421-1244, Ext. 279 Fax: 310-537-1173310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers800-421-1244 Fax: 310-537-3927310-537-3700

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

Extra Discounts!All parts orders which include complete part numbersand are received by our automated web parts ordersystem, or by fax qualify for the following extradiscounts:

Ordered Standard Stock ordersvia orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowanceswhen you order 10 or moreline items via Web or Fax!**FedEx Ground Service at no charge for freightNo other allowances on freight shipped by any othercarrier.

Place Your Parts Order Via Web or FaxFor Even More Savings!

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MULTIQUIP INC.18910 WILMINGTON AVENUEPOST OFFICE BOX 6254CARSON, CALIFORNIA 90749310-537-3700 • 800-421-1244FAX: 310-537-3927E-MAIL: [email protected]: multiquip.com

Direct TOLL-FREE accessto our Parts Department:

Toll-free nationwide — 800-427-1244


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DCA-125SSJU SERIES — SPECIFICATIONS


DCA-125SSJU SERIES — DIMENSIONS

Figure 1. Dimensions


This Owner's Manual has beendeveloped to provide completeinstructions for the safe andefficient operation of the MQ PowerModel DCA125SSJU SeriesWHISPERWATT™ GENERATOR.

Before using this GENERATOR, ensure that the operatingindividual has read and understands all instructions in thismanual.

Safety precautions should be followed at all times when operatingthis equipment. Failure to read and understand the SafetyMessages and Operating Instructions could result in injury toyourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

SAFETY MESSAGE ALERT SYMBOLS

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

DANGER: You WILL be KILLED orSERIOUSLY injured if you DO NOT followdirections.

WARNING: You CAN be KILLED orSERIOUSLY injured if you DO NOT followdirections.

CAUTION: You CAN be injured if youDO NOT follow directions.

HAZARD SYMBOLS

Engine exhaust gases contain poisonouscarbon monoxide. This gas is colorless andodorless, and can cause death if inhaled.NEVER operate this equipment in a confinedarea or enclosed structure that does notprovide ample free flow air.

Potential hazards associated with trowel operation will bereferenced with "Hazard Symbols" which appear throughoutthis manual, and will be referenced in conjunction with Safety"Message Alert Symbols".

Diesel fuel is extremely flammable, and itsvapors can cause an explosion if ignited. DONOT start the engine near spilled fuel orcombustible fluids. DO NOT fill the fuel tankwhile the engine is running or hot. DO NOToverfill tank, since spilled fuel could ignite if itcomes into contact with hot engine parts orsparks from the ignition system. Store fuel inapproved containers, in well-ventilated areasand away from sparks and flames. NEVERuse fuel as a cleaning agent.

Burn Hazards

Engine components can generate extreme heat.To prevent burns, DO NOT touch these areaswhile the engine is running or immediately afteroperations. NEVER operate the engine withheat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, orguards removed. Keep fingers, hands, hairand clothing away from all moving parts toprevent injury.

Explosive Fuel

Lethal Exhaust Gases

NOTE

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS


Accidental Starting

ALWAYS place the engine ON/OFFswitch in the OFF position, when thetrowel is not in use.

Over Speed Conditions

NEVER tamper with the factory settings of theengine governor or settings. Personal injuryand damage to the engine or equipment canresult if operating in speed ranges abovemaximum allowable.

Respiratory Hazard

ALWAYS wear approved respiratory protection.

ALWAYS wear approved eye and hearingprotection.

Sight and Hearing hazard

Equipment Damage Messages

Other important messages are provided throughout this manualto help prevent damage to your trowel, other property, or thesurrounding environment.

This generator, other property, orthe surrounding environment couldbe damaged if you do not followinstructions.

NOTE

DCA-125SSJU SERIES — SAFETY MESSAGE ALERT SYMBOLS


DCA-125SSJU SERIES — RULES FOR SAFE OPERATION

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Failure to follow instructions in this manual maylead to serious injury or even death! Thisequipment is to be operated by trained andqualified personnel only! This equipment is forindustrial use only.

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

GENERAL SAFETY

■ DO NOT operate or service this equipmentbefore reading this entire manual.

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

■ NEVER operate this equipment without properprotective clothing, shatterproof glasses, steel-toed boots and other protective devices requiredby the job.

■ NEVER operate this equipment when not feelingwell due to fatigue, illness or taking medicine.

■ NEVER operate this equipment under theinfluence or drugs or alcohol.

■ NEVER use accessories or attachments, which are notrecommended by MQ Power for this equipment. Damage tothe equipment and/or injury to user may result.

■ Manufacture does not assume responsibility for any accidentdue to equipment modifications.

■ Whenever necessary, replace nameplate, operation and safetydecals when they become difficult read.

■ ALWAYS check the machine for loosened threads or boltsbefore starting.

■ NEVER operate the generator in an explosive atmosphere ornear combustible materials. An explosion or fire could resultcausing severe bodily harm or even death.

■ High Temperatures – Allow the engine to cool beforeperforming service and maintenance functions. Contactwith hot! componentscan cause seriousburns.

■ The engine of thisgenerator requires anadequate free flow ofcooling air. NEVERoperate the generatorin any enclosed ornarrow area where freeflow of the air is restricted. If the air flow is restricted it willcause serious damage to the generator or engine andmay cause injury to people. The generator engine givesoff DEADLY carbon monoxide gas.

■ ALWAYS make sure generator is properly grounded.

■ NEVER use gas piping as an electrical ground.

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

■ ALWAYS make sure generator installation is accordance withnational and local electrical codes.

■ ALWAYS have a qualified electrician perform the generatorwiring installation.

■ NEVER power cables or cords lay in water.

■ NEVER stand in water while AC power from the generatoris being transfer to a load.

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

■ NEVER use a extension cord that is frayed or damaged wherethe insulation has been cut.

■ ALWAYS make certain that proper extension cord has beenselected for the job See Table 5.

■ The electrical voltage required to operate the generator cancause severe injury or even death through physical contactwith live circuits. Turn all circuit breakers OFF beforeperforming maintenance on the generator.

■ NEVER touch the hot exhaustmanifold, muffler or cylinder. Allowthese parts to cool before servicingengine or generator.



■ Backfeed to a utility system can cause electrocution and orproperty damage. DO NOT connect to any building's electricalsystem except through an approved device or after buildingmain switch is opened. ALWAYS have a licensed electricianperform the installation

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:DO NOT touch or open any of the belowmentioned components while thegenerator is running. Always allowsufficient time for the engine and generatorto cool before performing maintenance.

Radiator1. Radiator Cap - Removing the radiator cap while the engine

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

2. Coolant Drain Plug - Removing the coolant drain plugwhile the engine is hot will result in hot coolant to gush outof the coolant drain plug, therefore causing severe scaldingto any persons in the general area of the generator.

3. Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil to gush outof the oil drain plug, therefore causing severe scalding toany persons in the general area of the generator.

DANGERDANGERDANGERDANGERDANGER:


■ NEVER touch output terminals during operation. This isextremely dangerous. ALWAYS stop the machine andplace the circuit breaker in the “OFF” position when contactwith the output terminals is required. There exists thepossibility of electrocution, electrical shock or burn,which can cause severe bodily harm or even death!

Never use damaged or worn cables whenconnecting equipment to the generator.Make sure powerc o n n e c t i n gcables are

securely connected to thegenerator’s output terminals,insufficient tightening of theterminal connections may causedamage to the generator andelectrical shock.

.

Maintenance Safety■ NEVER lubricate components or attempt service on a running

machine.

■ ALWAYS allow the machine a properamount of time to cool before servicing.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and always replacebroken parts.

■ ALWAYS make sure that electrical circuits are properlygrounded per the National Electrical Code (NEC) and localcodes before operating generator. Severe injury or death! byelectrocution can result from operating an ungroundedgenerator.

■ ALWAYS be sure the operator is familiar with proper safetyprecautions 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 thereach of children.

■ ALWAYS read, understand, and followprocedures in Operator’s Manual beforeattempting to operate equipment.



POWERCORD

(POWER ON)

WETHANDS

NEVER grab ortouch a livepower cord withwet hands , thepossibility existsof electrical shock, electrocution, and evendeath!



■ NEVER Run engine without air filter. Severe enginedamage may occur.

■ ALWAYS service air cleaner frequently to prevent enginemalfunction.

■ ALWAYS disconnect the negative battery terminal beforeperforming service on the generator.

■ ALWAYS be sure the operator is familiar with proper safetyprecautions when operating the generator set.

■ ALWAYS store equipment properly when not in use.

■ DO NOT leave the generator running in the manual modeunattended.

■ DO NOT allow unauthorized people to operate thisequipment.

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

■ Refer to the John Deere Engine Manual for enginetechnical questions or information.

Battery

The battery contains acids that can cause injury to the eyesand skin. To avoid eye irritation, always wear safety glasses.Use well insulated gloves when picking up the battery. Usethe following guidelines when handling the battery:

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

2. DO NOT expose the battery toopen flames, sparks, cigarettesetc. The battery containscombustible gases and liquids. Ifthese gases and liquids come incontact with a flame or spark, anexplosion could occur.

3. ALWAYS keep the battery charged. If the battery is notcharged a buildup of combustible gas will occur.

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

5. ALWAYS recharge the battery in an vented airenvironment, to avoid risk of a dangerous concentrationof combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes incontact with your eyes, rinse eyes immediately with plentyof water, then contact the nearest doctor or hospital, andseek medical attention.

Pay close attention toventilation when operatingthe generator insidetunnels and caves. The

engine exhaust contains noxious elements.Engine exhaust must be routed to aventilated area.

DANGER:DANGER:DANGER:DANGER:DANGER:

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

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

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

Transporting

■ ALWAYS shutdown engine before transporting.

■ Tighten both fuel tank caps securely.

■ If generator is mounted on a trailer, make sure trailercomplies with all local and state safety transportationlaws. See next page “Towing Safety Precautions” forbasic towing techniques.


Emergencies

■ ALWAYS know the location of the nearest fire extinguisher.

■ ALWAYS know the location of the nearest and first aid kit.

■ In emergencies always know the location of thenearest phone or keep a phone on the job site.Also know the phone numbers of the nearestambulance, doctor and fire department. Thisinformation will be invaluable in the case of anemergency.

To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailerthat supports the generator and the towing vehicle are ingood operating condition and both units are mechanicallysound.

The following list of suggestions should be used when towingyour generator:

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

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chainsetc.

■ Check the tire air pressure on both towing vehicle andtrailer. Trailer tires should be inflated to 50 psi cold.Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

■ ALWAYS attach trailer’s safety chains to towing vehicleproperly.

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

■ The maximum speed for highway towing is 45 MPHunless posted otherwise. Recommended off-road towingis not to exceed 10 MPH or less depending on type ofterrain.

■ Place chock blocks underneath wheel to prevent rolling,while parked.

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

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

Towing Safety Precautions

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Conform to Department of Transportation(DOT) Safety Towing Regulations beforetowing generator.

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all timeswhen towing.

■ Raise and lock trailer wheel stand in up position whentransporting.

■ DOT Requirements include the following:


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


Figure 2. Typical Generator Grounding Application

DCA-125SSJU SERIES — INSTALLATION


Outdoor Installation

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

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

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

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

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

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

1. Use one of the following wire types to connect thegenerator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth groundrod should be buried aminimum of 8 ft. into the ground.

When connecting the generator toany buildings electrical systemALWAYS consult with a licensedelectrician.

DCA-125SSJU SERIES — INSTALLATION

NOTE

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Pay close attention to ventilation whenoperating the generator inside tunnels andcaves. The engine exhaust containsnoxious elements. Engine exhaust mustbe routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heat excessivelyand possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (suchas concrete) and set firmly on the foundation to isolatevibration of the generator when it is running. The generatormust set at least 6 inches above the floor or grade level (inaccordance to NFPA 110, Chapter 5-4.1). DO NOT removethe metal skids on the bottom of the generator. They are toresist damage to the bottom of the generator and to maintainalignment.


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

The following list of suggestions should be used when towingyour generator:

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Towing Safety Precautions

Check with your local county or state safetytowing regulations before towing yourgenerator.

■ Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating" (GVWR).

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chainsetc.

■ Check the tire air pressure on both towing vehicle andtrailer. Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

DCA-125SSJU SERIES — TOWING SAFTEY PRECAUTIONS

■ ALWAYS attach trailer’s safety chain to bumper of towingvehicle.

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

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place chocked blocks underneath wheel to preventrolling, while parked.

■ Place support blocks underneath the trailer’s bumper toprevent tipping, while parked.

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

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

■ Avoid sharp turns to prevent rolling.

■ Remove wheel stand when transporting.

■ DO NOT transport generator with fuel in tank.

Figure 3. Generator with Trailer


Explanation of Chart:This section is to provide the user with trailer service andmaintenance information. The service and maintenanceguidelines referenced in this section apply a wide range oftrailers. Remember periodic inspection of the trailer will en-sure safe towing of the equipment and will prevent damageto the equipment and personal injury.

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:

Brakes

Tires

Lug Nut Torquing

Suspension

Electrical

Brake Troubleshooting Tables

Use the following definitions when reading Table 2.

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

2. Braking System - System employed in stopping thetrailer. Typical braking systems are electric, surge, hy-draulic, hydraulic-surge and air.

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

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

DCA-125SSJU SERIES — TRAILER SPECIFICATIONS

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:ALWAYS make sure the trailer is in goodoperating condition. Check the tires forproper inflation and wear. Also check thewheel lug nuts for proper tightness.

5. Frame Length - Measurement is from fender to fender

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

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

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

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

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

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

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

13. Axle - Indicates the maximum weight the axle can sup-port in pounds, and the diameter of the axle expressedin inches. Please note that some trailers have a doubleaxle. This will be shown as 2-6000 lbs., meaning twoaxles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shockstransmitted through the wheels. Types of suspensionused are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are providedwith the trailer so the brake lights and turn signals canbe connected to the towing vehicle.

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



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

DCA-125SSJU SERIES — GENERATOR DECALS


DCA-125SSJU SERIES — GENERATOR DECALS


DCA-125SSJU SERIES — GENERAL INFORMATION

DCA-125SSJU Series FamiliarizationGeneratorThe MQ Power DCA-125SSJU Series is a 100 kW generator(Figure 4) that is designed as a high quality portable (requiresa trailer for transport) power source for telecom sites, lightingfacilities, power tools, submersible pumps and otherindustrial and construction machinery.Engine Operating PanelThe “Engine Operating Panel” is provided with the following:

TachometerWater Temperature GaugeOil Pressure GaugeCharging Ammeter GaugeEngine Throttle Handle (Up to S/N 77500507)Fuel Level GaugeEngine Speed Switch (S/N 7500508~)Cold Starting ButtonPanel LightPanel Light SwitchIgnition/Preheat Switch ( Up to S/N 77500507)Auto ON/OFF Engine Controller (S/N 7500508~)

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

Output Voltage Adjustment KnobFrequency Meter (Hz)AC Ammeter (Amps)AC Voltmeter (Volts)Ammeter Change-Over SwitchVoltmeter Change-Over SwitchVoltage RegulatorOver-Current Relay

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

Three 250 VAC output receptacles (CS-6369), 50 ampsThree auxiliary circuit breakers, 250V @50 ampsTwo 125 VAC output receptacles, (GFCI), 20 ampsTwo GFCI circuit breakers, 120V@ 20ampsFive output terminal lugs (3Ø power)

Control BoxThe “Control Box” is provided with the following:

3-Pole, 300 amp Main Circuit BreakerAutomatic Voltage RegulatorCurrent TransformerEmergency Relay

Open Delta Excitation SystemThe DCA-125SSJU Series Generator is equipped with the stateof the art "Open-Delta" excitation system. The open deltasystem consist of an electrically independent winding woundamong stationary windings of the AC output section.There are four connections of the open delta A, B, C and D.During steady state loads, the power from the voltage regulatoris supplied from the parallel connections of A to B, A to D, andC to D. These three phases of the voltage input to the voltageregulator are then rectified and are the excitation current for theexciter section.When a heavy load, such as a motor starting or a short circuitoccurs, the automatic voltage regulator (AVR) switches theconfiguration of the open delta to the series connection of B toC. This has the effect of adding the voltages of each phase otprovide higher excitation to the exciter section and thus bettervoltage response during the application of heavy loads.The connections of the AVR to the AC output windings are forsensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitationcurrent, offering maximum motor starting capabilities. Theexcitation does not have a "fixed ceiling" and respondsaccording the demands of the required load.EngineThe DCA-125SSJU Series Generator is powered by a4 cycle, water cooled, turbocharged John DeereModel 6068TF250 Diesel engine. This engine is designed tomeet every performance requirement for the generator. ReferenceTable 1 for engine specifications.In keeping with MQ Power's policy of constantly improving itsproducts, the specifications quoted herein are subject to changewithout prior notice.Mechanical Governor SystemThe mechanical governor system control the RPM of theengine. When the engine demands increase or decrease, themechanical governor system regulates the frequency varia-tion to ±.5%. The electronic governor option increasesfrequency variation to ±0.25%.Extension CablesWhen electric power is to be provided to various tools or loadsat some distance from the generator, extension cords arenormally used. Cables should be sized to allow for distance inlength and amperage so that the voltage drop between thegenerator and point of use (load) is held to a minimum. Use thecable selection chart (Table 5) as a guide for selecting properextension cable size.


DCA-125SSJU SERIES — MAJOR COMPONENTS

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The definitions below describe the controls and functions ofthe DCA-125SSJU Series "Generator Control Panel "(Figure 5).

1. Main Circuit Breaker – This three-pole, 300 amp mainbreaker is provided to protect the UVWO outputterminals from overload.

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

3. Ammeter Change-Over Switch – This switch allowsthe AC ammeter to indicate the current flowing to theload connected to any phase of the output terminals, orto be switched off. This switch does not effect thegenerator output in any fashion, it is for current readingonly.

4. Voltmeter Change-Over Switch – This switch allowsthe AC voltmeter to indicate phase to phase voltagebetween any two phases of the output terminals or tobe switched off.

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

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

7. AC Voltmeter – Indicates the output voltage presentat the UVWO terminals.

Located behind the generator control panel is the GeneratorControl Box. This box contains some of the necessaryelectronic components required to make the genertatorfunction.

The “Control Box” is equipped with the following majorcomponents:

Over-Current RelayVoltage RectiferStarter RelayEngine Controller (Computer Controlled)Current TransformerVoltage Selector Switch

Remember the overcurrentrelay monitors the currentflowing from the UWVO outputterminals to the load.

In the event of a short circuit orover current condition, it willautomatically trip the main 250amp breaker.

NOTE

To restore power to the UWVO output terminals, press thereset button on the overcurrent relay and place the maincircuit breaker in the closed position (ON).

Figure 5. Generator Control Panel

DCA-125SSJU SERIES — GENERATOR CONTROL PANEL


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

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

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

3. Oil Pressure Gauge – During normal operation thisgauge be should read in the “GREEN” zone. Whenstarting the generator the oil pressure may read a littlebit higher, but after the engine warms up the oil pressureshould return to the green zone.

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

5. Charging Ammeter Gauge – Indicates the currentbeing supplied by the engine’s alternator which providescurrent for generator’s control circuits and batterycharging system.

Figure 6. Engine Operating Panel Up To S/N 7500507

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

7. Tachometer – Indicates engine speed in RPM’s for 60Hz operation. This meter should indicate 1800 RPM’swhen the rated load is applied. In addition a built in hourmeter will record the number of operational hours thatthe generator has been in use.

8. Engine Speed Throttle- This lever controls the speedof the engine (low or high).

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

10. Cold Starting Button – Used to warm the engine glowplugs in cold weather conditions. Press and hold theengine cold starting button until the button illuminates.

11. Water Temperature Warning Light - Indicates if thecoolant is low. This warning will shut off the engine.

12. Oil Pressure Warning Light - This will indicate if theoil pressure is too low or high. This warning will shut offthe engine.

DCA-125SSJU SERIES — ENGINE OPERATING PANEL



Figure 7. Engine Operating Panel From S/N 7500508



The definitions below describe the controls and functions ofthe 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. Whenthe generator is not in use be sure to turn the panellight switch to the OFF position.

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

3. Oil Pressure Gauge – During normal operation thisgauge be should read between 42 to 71 psi. Whenstarting the generator the oil pressure mar read a littlebit higher, but after the engine warms up the oil pressureshould return to the green zone.

4. Water Temperature Gauge – During normal operationthis gauge be should read between 165o and 203oF.

5. Charging Ammeter Gauge – Indicates the currentbeing supplied by the engine’s alternator which providescurrent for generator’s control circuits and batterycharging system.

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

7. Tachometer – Indicates engine speed in RPM’s for 60Hz operation. This meter should indicate 1800 RPM’swhen the rated load is applied. In addition a built in hourmeter will record the number of operational hours thatthe generator has been in use.

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

9. Cold Starting Button – Used towarm the engine glow plugs in coldweather conditions. Press and holdthe engine cold starting button untilthe button illuminates.

A. Off/Manual/Auto Switch – This switch controls therunning of the generator. If this switch is left in the "OFF"position, the generator will not run. When this switch isset to the manual position, the generator will startimmediately.

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

B. Low Oil Pressure – Indicates the engine pressurehas fallen below 15 psi. The oil pressure is detectedusing variable resistive values from the oil pressuresending unit. This is considered a major fault.

C. High Coolant Temperature – Indicates the enginetemperature has exceeded 215° F. The enginetemperature is detected using variable resistive valuesfrom the temperature sending unit. This is considereda major fault.

D. Overcrank Shutdown – Indicates the unit hasattempted to start a pre- programmed number of times,and has failed to start. The number of cycles andduration are programmable. It is pre-set at 3 cycleswith a 10 second duration. This is considered a majorfault.

E. Overspeed Shutdown – Indicates the engine isrunning at an unsafe speed. This is considered a majorfault.

F. Engine Running – Indicates that engine is runningat a safe operating speed.

10. Auto On/Off EngineController – This controllerhas a vertical row of statusLED's (inset), that when lit,indicate that an enginemalfunction (fault), has beendetected. When a fault hasbeen detected the enginecontroller will evaluate the fault.Any major fault will cause thecontroller to shutdown thegenerator.

During cranking cycle , The MPEC will attempt to crank theengine for 10 seconds before disengaging. If the enginedoes not engage (start) by the third attempt, the engine willbe shutdown by the engine controller’s " Over CrankProtection" mode. If the engine engages at a speed (RPM's)that is not safe, the controller will shutdown the engine byinitializing the "Over Speed Protection" mode.

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


Output Terminal FamiliarizationThe “Output Terminal Panel ” (Figure 8) is provided withthe following:

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

Five (5) Output Terminal Lugs

Output Terminal PanelThe Output Terminal Panel ( Figure 8) shown below islocated on the right-hand side (left from control panel) of thegenerator. Lift up on the cover to gain access to receptaclesand terminal lugs.

NOTETerminal legs “O” and “Ground”are considered bonded grounds.

Figure 8. Output Terminal Panel

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL FAMILIARIZATION


120 VAC GFCI ReceptaclesThere are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)recepacles provided on the output terminal panel. Thesereceptacles can be accessed in any voltage selector switchposition. Each receptacle is protected by a 20 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) of bothGFCI receptacles is dependent on the load requirements ofthe UVWO terminals.

Pressing the reset button resets the GFCI receptacle afterbeing tripped. Pressing the "Test Button" (See Figure 9) inthe center of the receptacle will check the GFCI function.Both receptacles should be tested at least once a month.

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

Each auxiliary receptacle is protected by a 50 amp circuitbreaker. These breakers are located directly above the GFCIreceptacles. Remember the load output (current) on all threereceptacles is dependent on the load requirements of theUVWO terminals.

Turn the voltage regulator control knob (Figure 11) on thecontrol panel to obtain the desired voltage. Turning the knobclockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 10. 240 VAC Twist-LockAuxiliary Receptacles


Twist Lock Dual Voltage 120/240 VAC ReceptaclesThere are three 240 VAC, 50 amp auxiliary twist-lock(CS-6369) recepacles (Figure 10) provided on the outputterminal panel.These receptacles can only be accessedwhen the voltage selector switch is placed in the single-phase 240/120 position.

Removing the Plastic Face Plate (UVWO Terminals)The UVWO terminal lugs are protected by a plastic faceplate cover (Figure 12). Un-lock the locking latch, and lift theterminal cover to gain access to the plastic face plate.Remove the screws securing the face plate to the terminalenclosure, then lift the plastic hinged face plate.After the load wires have been securely attached to theUVWO terminals, reinstall the plastic face plate. Place theterminal cover in the down position and secure the lockinglatch.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (UVWO Terminals)


Figure 13. Connecting Loads

Connecting LoadsLoads can be connected to the generator by the UVWO terminallugs or the convienience receptacles. (See Figure 13). Makesure to read the operation manual before attempting to connecta load to the generator.

To protect the UVWO output terminals from overload, a 3-pole, 300 amp, main circuit breaker is provided. Make sureto switch ALL circuit breakers to the "OFF" position prior tostarting the engine.


Over Current RelayAn over current relay (Figure 14) is connected to the maincircuit breaker. In the event of an overload, both the circuitbreaker and the over current relay may trip. If the circuitbreaker 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.

Figure 14. Over Current Relay

Maximum OutputThe entire load connected to the UVWO terminal lugs, duplexand auxiliary receptacles must not exceed 110 kw in standby or100 kw in prime output.


DCA-125SSJU SERIES — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage andfrequency requirements are satisfactorily supplied by thegenerator for operating the equipment.

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

Motors and motor-drivenequipment draw much greatercurrent for starting than duringoperation.

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

If wattage is not given on the equipment'sname plate, approximate wattage may bedetermined by multiplying nameplatevoltage by the nameplate amperage.

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

Before connecting this generator to anybuilding’s electrical system, a licensedelectrician must install an isolation (transfer)switch. Serious injury or death may resultwithout this transfer switch.

CAUTION:

If 3Ø load (kVA) is not given onthe equipment nameplate,approximate 3Ø load outputmaybe determined by multiplyingvoltage by amperage by 1.732.

When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of up tothe generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, acapacity of up to the generating set’s rated output (kW)multiplied by 0.6 can be used.

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

NOTE

WATTS = VOLTAGE x AMPERAGE

Three Phase Load

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

NOTE

An inadequate size connecting cable which cannot carry therequired load can cause a voltage drop which can burn outthe appliance or tool and overheat the cable. See Table 5.

NOTE

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Generator Output VoltagesA wide range of voltages are available to supply voltage formany different applications. Voltages are selected by usingthe voltage selector switch (Figure 15). To obtain some ofthe voltages as listed in Table 6 (see below) will require afine adjustment using the voltage regulator (VR) controlknob located on the control panel.

Voltage Selector SwitchThe voltage selector switch (Figure 15) is located abovethe UVWO Hard Wire Hook-up Panel. It has been providedfor ease of voltage selection.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:NEVER change the position of the voltageselector switch while the engine is running.ALWAYS place circuit breaker in the openposition before selecting voltage.

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protectthe generator and load from being switched while the engineis running. To lock the voltage selector switch, press andhold the red button located at the bottom of the switch.

Figure 15. Voltage Selector Switch

DCA-125SSJU SERIES — GENERATOR OUTPUTS

Generator AmperageTables 7 and 8 describe the generator’s current output capa-bility for both 1Ø-phase and 3Ø phase applications.

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GFCI Receptacle Load CapabilityThe 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.

Tables 9 and 10 show what amount of current is available atthe GFCI receptacles when the UVWO terminals and twistlock receptacles are in use. Be careful that your load doesnot to exceed the available current capability at the recep-tacles.

DCA-125SSJU SERIES — GENERATOR OUTPUTS/GAUGE READING

How to Read the Output Terminal Gauge.The gauge and selector switch on the control panel DO NOTeffect the generator output. They are provided to help ob-serve how much power is being supplied, produced at theUVWO terminals lugs.

When the Voltage selector switch is in the 3Ø,240/139Vposition (See Figure 16), place the AC Voltmeter Change-Over Switch (Figure 17) to the W-U position and theAC Ammeter Change-Over Switch (Figure 19) to the U orW position to read the output on the selected leg.

Figure 16. Voltage Selector Switch 240/139V Three PhasePosition (for 3Ø, 208V, 120V voltage)

Figure 17. AC VoltmeterChange-Over Switch

Figure 18 AC VoltmeterGauge

(Volt reading on W-U Lug)

Use this position for3Ø, 208V/1Ø,120V

A

0

4060

75

20

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

Figure 19. AC AmmeterChange-Over Switch

The ammeter and voltmetergauges are only active when theUVWO terminals are in use.

NOTE

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Figure 21. Voltage Selector Switch 240/139VThree-Phase Position

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output VoltagesVarious output voltages can be obtained using the UVWOoutput terminal lugs. The voltages at the terminals are de-pendent on the position of the Voltage Selector Switch andthe adjustment of the Voltage Regulator Control Knob.

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

3Ø 240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139position as shown in Figure 21.

Figure 22. UVWO Terminal Lugs240/139V Three Phase Connections

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

3. Turn the voltage regulator knob (Figure 23) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output.

3Ø 208V/1Ø120V UVWO Terminal Output Voltages1. Place the voltage selector switch in the 3Ø 240/139

position as shown in Figure 24.

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

Use this position for3Ø-208 or 1Ø120V.



Figure 26. Voltage Regulator Knob (208V)

NOTE

To achieve a 3Ø 208Voutput the voltage selectorswitch must be in the 3Ø-240/139 position and thevoltage regulator must beadjusted to 208V.

Figure 25. UVWO Terminal Lugs3Ø-208V/120V Connections

Figure 24. Voltage SelectorSwitch 3Ø-208V/1Ø-120VThree-Phase Position


Figure 27. Voltage Selector Switch 480/277V Three-Phase Position

3Ø 480/277 UVWO Terminal Output Voltages


Figure 28. UVWO Terminal Lugs240/139V Three Phase Connections



1Ø 240V/120V UVWO Terminal Output Voltages


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



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

Figure 31. UVWO Terminal Lugs1Ø-240V/120V Connections

DCA-125SSJU SERIES — OUTPUT TERMINAL PANEL CONNECTIONS

Figure 30. Voltage Selector Switch 240/120V Single-Phase Position


DCA-125SSJU SERIES — PRE-SETUP

Figure 33. Engine Oil Dipstick

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

Circuit Breakers

To protect the generator from an overload, a 3-pole, 300 amp,main circuit breaker is provided to protect the UVW outputterminals from overload. In addition two single-pole, 20 ampGFCI circuit breakers are provided to protect the GFCIreceptacles from overload. Three 50 amp load circuit breakershave also been provided to protect the auxiliary receptaclesfrom overload. Make sure to switch ALL circuit breakers tothe "OFF" position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but DO NOT overfill. Make sure the generator is level.and verify that the oil level is maintained between the twonotches (Figure 33) on the dipstick. See Table 11 for properselection of engine oil.

API Service Classification CH-4API Service Classification CG-4API Service Classification CF-4ACEA Specification E3ACEA Specification E2

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

WARNING:WARNING:WARNING:WARNING:WARNING:ONLY properly trained personel who haveread and understand this section should refillthe double fuel tank system.Use #2 diesel fuel.

Figure 34. Double Fuel Tank System

Fuel spillage on a hot! engine can causea fire or explosion. If fuel spillage occurs,wipe up the spilled fuel completely toprevent fire hazards. NEVER! smokearound or near the generator.


Refilling the Fuel System

The DCA150SSVU genset may (if equipped with a trailer orskid) have a double fuel tank system (Figure 34), whichconsists of an internal generator fuel tank, and a trailermounted fuel tank. It is also possible the genset can beequipped with a skid mounted fuel tank (Figure 35). Theskid type fuel system does not use the internal generatorfuel tank.

Use the instructions in this section that applies to your typeof fuel tank system.

ALWAYS fill the fuel tank with clean and fresh #2 dieselfuel. DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishingfuel.The fuel tank cap must be closed tightly after filling.Handle fuel in a safety container. If the container does nothave a spout, use a funnel. Wipe up any spilled fuelimmediately.

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Refueling Procedure:

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

2. Trailer Fuel Tank First – The trailer fuel tank is theprimary fuel tank and holds a larger capacity of fuel.The fuel in the trailer will be filtered and sent to theengine. ALWAYS fill trailer fuel tank (Figure 37) first.

Figure 37. Fuel Tank Filling Order

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:


WARNING:WARNING:WARNING:WARNING:WARNING:

Figure 36. Only Fill on Level Ground

ONLY! use #2 diesel fuel whenrefueling.

Diesel fuel and its vapors are dangerousto your health and the surroundingenvironment. Avoid skincontact and/or inhalingfumes.

ALWAYS! fill trailer tank first with #2 dieselfuel, before filling secondary internal tank.

ALWAYS! place trailer on firm level groundbefore refueling.

NOTE

NOTEFuel from the secondary innertank will eventually drain into theprimary trailer tank.

Figure 35. Skid Type Fuel Tank System



3. NEVER overfill trailer fuel tank – It is important toread the trailer fuel gauge when filling trailer fuel tank.DO NOT wait for fuel to rise in filler neck. See Figure 38.

Figure 38. Full Trailer Tank

Figure 39. Filling Secondary Internal Fuel Tank

Figure 41. Fuel Expansion

WARNING:WARNING:WARNING:WARNING:WARNING:DO NOT OVER-FILL fuel system. Leave roomfor fuel expansion . Fuel expands when heated.

4. Once the trailer tank is full, the secondary inner tankcan be filled (See Figure 39). Notice how the trailerfiller tube level rises when the internal tank is filled.

5. Figure 40 below reflects a full fuel system.

6. Fuel from the engine return line will drain into the secondaryinternal fuel tank. This fuel will eventually drain into theprimary trailer tank in order to return to the engine.

Figure 40. Full Fuel System

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


Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)Use only drinkable tap water. If hard water or water withmany impurities is used, the inside of the engine and radiatormay become coated with deposits and cooling efficiencywill be reduced.

An anticorrosion additive added to the water will help preventdeposits and corrosion in the cooling system. See the enginemanual for further details.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:If adding coolant/antifreezemix to the radiator, DONOT remove the radiatorcap until the unit has completely cooled. The

possibility of hot! coolant exists which can cause severeburns.

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

Operation Freezing Weather

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

Cleaning the Radiator

The engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the machine isdangerous, so clean only with the engine turned off and thenegative battery terminal disconnected.

Air Cleaner

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

Fan Belt Tension

A slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with the JohnDeere Engine Owner's Manual.

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

Figure 42. Fan Belt Tension

When the antifreeze is mixed withwater, the antifreeze mixing ratiomust be less than 50%.

NOTE

NEVER! place hands nearthe belts or fan while thegenerator set is running.


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When connecting battery do the following:

1. NEVER connect the battery cables to the batteryterminals when the ignition switch is in either the Pre-Heat, RUN, or START position. ALWAYS make surethat the ignition switch is in the STOP position whenconnecting the battery.

2. Place a small amount of battery terminal treatmentcompound around both battery terminals. This will ensurea good connection and will help prevent corrosion aroundthe battery terminals.

Figure 43. Battery Connections

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:ALWAYS disconnect the negativeterminal FIRST and reconnectnegative terminal LAST.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:Inadequate battery connections may causepoor starting of the generator, and createother malfunctions.

Alternator

The polarity of the alternator is negative grounding type. Whenan inverted circuit connection takes place, the circuit will bein short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of waterinto the alternator leads an electrolyte corrosion causing analternator 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 wiringor 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 forwear and tightness. Tighten all hose clamps and check hosesfor leaks.

If any hose (fuel or oil) lines are defective replace themimmediately.

If the battery cable is connectedincorrectly, electrical damage to thegenerator will occur. Pay closeattention to the polarity of thebattery when connecting thebattery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level are notproperly maintained. Add only distilled water whenreplenishment is necessary.

DO NOT over fill. Check to see whether the battery cablesare loose. Poor contact may result in poor starting ormalfunctions. Always keep the terminals firmly tightened.Coating the terminals with an approved battery terminaltreatment compound. Replace battery with onlyrecommended type battery. The battery type used in thisgenerator is BCI Group 27.

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

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 43) are properlyconnected to the battery terminals as shown below. TheRED cable is connected to the positive terminal of the battery,and the BLACK cable is connected to the negative terminalof the battery.


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

WARNING:WARNING:WARNING:WARNING:WARNING:The engine's exhaust contains harmfulemissions. ALWAYS have adequateventilation when operating. Direct exhaustaway from nearby personnel.

Before StartingEngine Operating Panel S/N 73002140 and below

Steps 1 thru 19 are referenced forEngine Operating Panels up toS/N 7500705 (Figure 44). This unithas a ignition key switch and athrottle lever. It does not have anMPEC unit.

NOTE

Figure 44. Engine Operating PanelUp to S/N 7500507

Figure 46. Load Connections

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

Figure 47. Engine Enclosure Doors

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 fromslipping out.

1. Place the main, G.F.C.I. and aux. circuit breakers (Figure 45)in the “OFF” position prior to starting the engine.

2. Connect the load to the UVWO terminals or auxiliaryreceptacles as shown in Figure 46. These loadconnection points can be found on the output terminalpanel. To gain access to the UVWO terminals or otherpower receptacles, unlock the access cover and lift thedoor.

Figure 45. Main, Aux. and GFCICircuit Breakers (OFF)

5. When starting the generator in COLD weather conditions,turn the ignition key to the “PREHEAT ” position (Figure 48). Inwarm weather conditions, pre-heating is not necessary. Skip tostep 7.

Figure 48. Engine Ignition Switch (Pre-Heat)

NEVER! manually start the engine with themain, GFCI or auailliary circuit breakersin the ON (closed) position.

CAUTION:



Figure 56. Voltage Adjust Control Knob

Figure 57. Ammeter (No Load)

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

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

Figure 55. Voltmeter

Figure 49. Cold Starting Button

8. Place the engine throttle control in the “LOW” position(Figure 51).

Figure 52. Engine Ignition Switch (Start)

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

Figure 51. Engine Throttle Control

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.

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

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

Figure 58. Oil Pressure Gauge

STARTING (MANUAL)Engine Operating Panel up to S/N 7500507

Figure 54. Frequency Meter (Hz)

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

7. Place the voltage selector switchin the desired voltage position(Figure 50).

Figure 50. Voltage SelectorSwitch

Figure 53. Engine Throttle Control



Figure 60. Engine Tachometer Gauge

16. The tachometer gauge (Figure 60) will indicate thespeed of the engine when the generator is operating.Under normal operating conditions this speed isapproximately 1800 RPM’s.

15. The coolant temperature gauge (Figure 59) will indicatethe coolant temperature. Under normal operatingconditions the coolant temperature should be between165 and 215 degrees Fahrenheit (Green Zone).

Figure 59. Coolant Temperature Gauge

Figure 61. Main, Aux. and GFCICircuit Breakers (ON)

17. Place the main, GFCI, and aux. circuit breakers in the“ON” position (Figure 61).

18. Observe the generator's ammeter (Figure 62) and verifyit reads the anticipated amount of current with respectto the load. The ammeter will only display a currentreading if a load is in use.

Figure 62. Ammeter (Load)

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



Figure 66. Auto-Off/Reset-Manual Switch

Figure 65. Engine Speed Switch (Low)

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

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

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

Figure 67. Engine Speed Switch (High)

WARNING:WARNING:WARNING:WARNING:WARNING:The engine's exhaust contains harmfulemissions. ALWAYS have adequateventilation when operating. Direct exhaustaway from nearby personnel.

NEVER! manually start the engine with themain, GFCI or auailliary circuit breakers inthe ON (closed) position.

CAUTION:

Before StartingEngine Operating Panel S/N 7500508~

Steps 20 thru 31 are referencedfor Engine Operating Panel S/N7500508~ (Figure 63). This unitdoes not have a key ignitionswitch or a throttle lever. It doeshave an “engine speed switch”that is used in conjunction withthe MPEC unit.

Figure 63. Engine Operating PanelS/N 7500508~

20. Perform steps 1 through 4 in the Before Starting section(page 41-42) as outlined in the Manual GeneratorStart-up Procedure (Engine Operating Panel up toS/N 73002140).

21. In cold weather conditions, perform step 6 in the BeforeStarting section (page 42) as outlined in the ManualGenerator Start-up Procedure (Engine Operating Panelup to S/N 7500508). Otherwise skip to step 22.

26. Verify that the "Engine Running" status LED on the MPECunit (Figure 68) is "ON" (lit) after the engine has been started.

Figure 68. Engine Running LED (ON)

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

Figure 64. Voltage SelectorSwitch

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


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

Before connecting thisgenerator to anybuilding’s electricalsystem, a licensedelectrician must installan isolation (transfer)

switch. Serious injury or death may result without thistransfer switch.

DANGER:

28. Perform steps 20 through 22 in the Before Startingsection (page 44) as outlined in the Manual StartingProcedure.

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

31. Continue to follow the steps outlined in the “ManualStart-up” procedure (start at step 11, page 42).

Figure 69. Engine Speed Switch (High)

When running the generator in the “AUTO“mode, remember the generator can start upat any time without warning. NEVER attemptto perform any maintenance when thegenerator is in the auto mode.

WARNING:

When connecting the generator to aisolation (transfer) switch, ALWAYS havepower applied to the generator's internalbattery charger. This will ensure that theengine will not fail due to a dead battery.

CAUTION:

Figure 70. Off/Manual Auto Switch (AUTO)

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

NOTE

When the generator is set in the“AUTO” mode, the generator willautomically start in the event ofcomercial power falling below aprescribed level by means of acontact closure that is generatedautomatically by a transfer switch.

The Engine Speed Switch must be setto the “HIGH” position when running in theAuto-Start mode. Failing to set the switchin the proper position can result in damageto your generator when it turns on.

CAUTION:


DCA-125SSJU SERIES — GENERATOR SHUT-DOWN PROCEDURE

Shutdown Procedure - Engine Controller(S/N 7500508~)To shutdown the generator use the following procedure:

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

2. Place the engine speed switch in the “LOW” position(Figure 73).

Figure 73. Engine Speed Switch (Low)

3. Let the engine cool by running it for 3-5 minutes with noload applied.

4. Place the Auto-Off/Reset-Manual switch (Figure 74) tothe OFF/Reset position.

Figure 74. Off/Manual Auto Switch (Off)

5. Verify that the all status LED on the MPEC display(Figure 68) are "OFF" (not lit).

6. Remove all loads from the generator.

Shutdown Procedure - Ignition Switch(Up to S/N 7500507)To shutdown the generator use the following procedure:

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

2. Place the engine throttle control in the “LOW” position(Figure 71).

Figure 71. Engine Throttle Control (Low)

3. Let the engine cool by running it for 3-5 minutes with noload applied.

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

Figure 72. Engine Ignition Switch (Stop)

5. Remove all loads from the generator.

NEVER stop the engine suddenly exceptin an emergency. DO NOT use theemergency stop switch a as method ofshutting down the generator. This switch isONLY to be used in the event of anemergency.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTION:

Emergency Shutdown Procedure - Engine Controller(S/N 7500508~)1. To shut-down the engine in the event of an emergency,

switch the MAIN, GFCI and LOAD (Figure 45) circuitbreakers to “OFF” position.

2. Place the Auto-Off/Reset-Manual switch (Figure 74) tothe “OFF/Reset“ position.

Emergency Shutdown Procedure - Ignition Switch(Up to S/N 7500507)1. To shut-down the engine in the event of an emergency,

switch the MAIN, GFCI and LOAD (Figure 61) circuitbreakers to “OFF” position.

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


DCA-125SSJU SERIES — MAINTENANCE

Service DailyIf the engine is operating in very dusty or dry grass conditions, aclogged air cleaner will result. This can lead to a loss of power,excessive carbon buildup in the combustion chamber and highfuel consumption. Change air cleaner more frequently if theseconditions exists.

Fuel AdditionAdd diesel fuel (the grade may vary according to season andlocations). Always pour through the mesh filter.

Removing Water from the Fuel TankAfter prolonged use, water and other impurities accumulate inthe bottom of the tank. Occasionally remove the drain cock anddrain the contents. During cold weather, the more empty volumeinside the tank, the easier it is for water to condense. This can bereduced by keeping the tank full with diesel fuel.

General InspectionPrior to each use, the generator should be cleaned and inspectedfor deficiencies. Check for loose, missing or damaged nuts, boltsor other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air CleanerEvery 50 hours: Remove air cleaner element and clean the heavyduty paper element with kerosene, or foam element with liquiddetergent and hot water. Wrap foam element in a cloth andsqueeze dry. For heavy duty paper element, wipe excesskerosene with towel.

Air Cleaner with Dust IndicatorThis indicator is attached to the air cleaner. When the air cleanerelement is clogged, air intake restriction becomes greater andthe dust indicator signal shows “RED” meaning the elementneeds changing. After changing the air element, press the dustindicator button to reset the indicator.

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Generator StorageFor longe term storage of the generator the following isrecommended:

Fill the fuel tank completely. Treat with a fuel stabilizerif necessary.Completely drain the oil from the crankcase and refill ifnecessary with fresh oil.Clean the entire generator, internal and external.Cover the generating set and store in a clean, dry place.Disconnect the battery.Make sure engine coolant is at proper level.If generator is mounted on a trailer, jack trailer up andplace on block so tires do touch the ground or removetires.

Flushing Out Radiator and Replacing CoolantOpen both cocks located at the crankcase side and atthe lower part of the radiator and drain coolant. Open theradiator cap while draining. Remove the overflow tankand drain.Check hoses for softening and kinks. Check clamps forsigns of leakage.Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DO NOTclean radiator core with any objects, such as ascrewdriver.Tighten both cocks and replace the overflow tank.Replace with coolant (Table 12 for correct mixture).Close radiator cap tightly.

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Allow engine to cool when flushing outradiator. Flushing the radiator while hot!will damage radiator.

Air RemovalIf air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure.To restart after running out of fuel, turn the switch to the“ON” position for 15-30 seconds. Try again, if needed. Thisunit is equipped with an automatic air bleeding system.

Cleaning the Fuel StrainerClean the fuel strainer if it contains dust or water. Removedust or water in the strainer cap and wash it in gasoline.Securely fasten the fuel strainer cap so that fuel will notleak. Check the fuel strainer every 200 hours of operation oronce a month.

Check Oil LevelCheck the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 33.

Replacing Oil FilterDetach the oil filter by loosening center bolt and removethe element together with the filter body.Apply a film of oil to the gasket for the cartridge.Install the filter body together with the element and fixthem by tightening the center bolt.After the oil cartridge has been replaced, the engine oilwill drop slightly. Run the engine for a while and checkfor leaks before adding more oil if needed. Cleanexcessive oil from engine.

Replacing Fuel FilterReplace the fuel filter cartridge with new one every 400hours or so.Loosen the drain plug at the lower top of the fuel filter.Drain the fuel in the fuel body together with the mixedwater. DO NOT spill the fuel during disassembly.Vent any air.

Feed Pump Strainer CleaningThe strainer is incorporated in the feed pump inlet side jointbolt. Clean the strainer with compressed air and rinse it inthe fuel oil.



To ensure adequate startingcapability, always have powerapplied to the generator'sinternal battery charger.

NOTE

Figure 75. Battery Charger &Jacket Water Heater Power Connections

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

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

The purpose of these receptacles is to provide power viacommercial power to the jacket water heater and internalbattery charger.

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

When using the generator in hot climates there is no reasonto apply power to jacket water heater. However, if thegenerator will be used in cold climates it is always a goodidea to apply power to the jacket water heater at all times. Toapply power to the jacket water heater simply apply power tothe jacket water heater receptacle via commercial powerusing an power cord of adequate size.

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


DCA-125SSJU SERIES — TRAILER BRAKES MAINTENANCE

Hydraulic Surge BrakesHydraulic surge brakes (Figure 76) should not require anyspecial attention with the exception of routine maintenancesuch as shoe and lining replacement. Brake lines should beperiodically checked for cracks, kinks, or blockage.

Figure 76. Hydraulic Brake Components

BrakesTrailer brakes should be inspected the first 200 miles ofoperation. This will allow the brake shoes and drums to seatproperly. After the first 200 mile interval, inspect the brakesevery 3,000 miles. If driving over rough terrain, inspect thebrakes more frequently.

Figure 74 displays the major hydraulic surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps 1through 8 as listed below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate thestar wheel of the adjuster assembly to expand the brakeshoes.

5. Adjust the brake shoes outward until the pressure of thelining against the wheel drum makes the wheel difficultto turn.

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

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

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

ActuatorHydraulic surge braking requires the installation of an actuatorat the tongue of the trailer. Remember the surge or push ofthe trailer toward the tow vehicle automatically synchronizesthe trailer brakes with the tow vehicle brakes. As the trailerpushes against the tow vehicle the actuator telescopestogether and applies force to the master cylinder, supplyinghydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator ” to makesure that it is functioning correctly. Never use an undersizeactuator.

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Tires/Wheels/Lug NutsTires and wheels are a very impor tant and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

CAUTION:DO NOT attemptto repair or modifya wheel. DO NOTinstall in innertube to correct a leak through the rim. If the

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

Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot!. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.

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

CAUTION:ALWAYS wear safety glasses when removingor installing force fitted parts. Failure to complymay result in serious injury.

SuspensionThe leaf suspension springs and associated components(Figure 77) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged par ts(suspension) immediately. Torqued suspension componentsas detailed in Table 17.

Figure 77. Major Suspension Components

DCA-125SSJU SERIES — TRAILER MAINTENANCE

WEAR PATTERN CAUSE SOLUTION

Center Wear Over Inflation.Adjust pressure toparticular load per tiremanufacturer.

Edge Wear Under Inflation.Adjust pressure toparticular load per tiremanufacturer.

Side Wear Loss of camberor overloading.

Make sure load doesnot exceed axle rating.Align wheels.

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance. Check bearing adjustmentand balance tires.

Flat SpotsWheel lockup &tire skidding.

Avoid sudden stops whenpossible and adjust brakes.

TABLE 16. TIRE WEAR TROUBLESHOOTING

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SHACKLE BOLTSPRING EYE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.LOCKING NUTS OR COTTER PINS ARE PROVIDEDTO RETAIN NUT-BOLT ASSEMBLY.

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Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure 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 NOTtorque the wheel lug nuts all the way down. Tighten eachlug 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.

NEVER use an pneumatic airgun to tighten wheel lug nuts.

Figure 78. Wheel Lug Nuts Tightening Sequence

DCA-125SSJU SERIES — TRAILER MAINTENANCE

stnemeriuqeReuqroTeriT.81elbaT

eziSleehW ssaPtsriFSBL-TF

ssaPdnoceSSBL-TF

ssaPdrihTSBL-TF

"21 52-02 04-53 56-05

"31 52-02 04-53 56-05

"41 52-02 06-05 021-09

"51 52-02 06-05 021-09

"61 52-02 06-05 021-09

NOTE


DCA-125SSJU SERIES — TRAILER WIRING DIAGRAM

Figure 79. Trailer/Towing Vehicle Wiring Diagram


DCA-125SSJU SERIES — GENERATOR WIRING DIAGRAM

Figure 80. Generator Wiring Diagram


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

Figure 81. Engine Wiring Diagram(Ignition Switch)


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

Figure 82. Engine Wiring Diagram (Engine Controller)


NOTE PAGE


DCA-125SSJU SERIES — TROUBLESHOOTING (ENGINE)

GNITOOHSELBUORTENIGNE.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxEwoltalioenigneroleuf

?erutarepmet.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS?gniraebrorenilrednilyc,notsip .ecalperroriapeR

morfkaelnoisserpmoC?rednilyc

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS?gninoitcnuflamretratS .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

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


DCA-125SSJU SERIES — TROUBLESHOOTING (ENGINE)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.91ELBAT


.htoomstonsinoituloverenignE

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI?erusserp .tsujdA

rokcutselzzonnoitcejnI?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP?kcuts .ecalperroriapeR


?noisserpmoctneicifeD .ecnaraelcpottsujdA

yargkradrokcalbrehtiE.devresbosisagtsuahxe

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD


otmeesstrapgnivoms'enignE?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR.redlohelzzon


DCA-125SSJU SERIES — TROUBLESHOOTING (GENERATOR)

GNITOOHSELBUORTROTARENEG.02ELBAT


tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of abreakdown, use the table shown below for diagnosis based on the Generator Troubleshooting (Table 20). If the problemcannot be remedied, consult our company's business office or service plant.


DCA-125SSJU SERIES — TROUBLESHOOTING (MPEC)

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

GNITOOHSELBUORTRELLORTNOCENIGNE.12ELBAT

notpmyS esuaCelbissoP noituloS

thgilerusserpliowoL.nosi

?levelliowoL .levelliolliF

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?rellortnoCninoitnuflamyaledemiT .relaedotrefeR

?detrohseriW .eriwriaper/tcepsnI

thgilleveltnaloocwoL.nosi

?leveltnaloocwoL .leveltnalooclliF

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

tnaloochgiH.nosithgilerutrepmet

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?neposrooD .sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?dedaolrevogniebrotareneG .daolecuder/kcehC

?eruliaftatsomrehT .tatsomrehtecalpeR

?dekcolbekatniriA .sekatniriallaraelC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

.nosithgilknarcrevO?leuFwolrooN .levelleuflliF

?detarbilacebotsdeenrellortnoC .relaedotrefeR

.nosithgildeepsrevO

?hgihootdeepsenigneMPR .MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenignE .relaedotrefeR

ro)s(thgilUPMfossoL.no

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipcitengaM .pukcipcitengamnaelC


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 numberrange (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that thecorresponding part is utilized only with this specific model numberor 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 samereference number is listed, the lastone listed indicates newest (orlatest) part available.

The contents of this catalog aresubject to change without notice.

NOTE

NOTE


DCA-125SSJU & DCA-125SSJU2W/JOHN DEERE 6080TF250 DIESEL ENGINE1 TO 3 UNITS

DCA-125SSJU SERIES — SUGGESTED SPARE PARTS

Qty. P/N Description Remarks1 0601820671 AUTOMATIC VOLTAGE REGULATOR1 0601840073 RHEOSTAT VOLTAGE REGULATOR1 0601840121 KNOB, RHEOSTAT1 47230107 KNOB, SELECTOR SWITCH1 M3310500003 RADIATOR HOSE, UPPER ....................... S/N 7500001TO75003071 M3310500403 RADIATOR HOSE, UPPER ....................... S/N 7500307~1 M3310500103 RADIATOR HOSE, LOWER ....................... S/N 7500001TO75003071 M3310500503 RADIATOR HOSE, LOWER ....................... S/N 7500307~5 0602041290 OIL FILTER5 0602042590 FUEL FILTER5 0602046377 AIR ELEMENT3 0602042420 FUEL FILTER, FUEL TANK1 0602122272 UNIT, OIL PRESSURE1 0602123261 UNIT, WATER TEMPERATURE1 0601810245 BULB, ALARM LAMP1 R1234145 FAN BELT1 0602122281 OIL SHUTDOWN SWITCH ........................ S/N 7500001TO75005071 0602100056 STARTER SWITCH1 AR51481 KEY, STARTER SWITCH1 M9310000103 ENCLOSURE CAP1 M1483600204 ENCLOSURE CAP CHAIN ASSEMBLY1 ECU9988NJD CONTROLLER ECU

Part number on this Suggested SpareParts list may supercede/replace theP/N shown in the text pages of this book.

NOTE


DCA-125SSJU SERIES — NAMEPLATE AND DECALS

NAMEPLATE AND DECALS


DCA-125SSJU SERIES — NAMEPLATE AND DECALS

NAMEPLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS1 M1550000204 DECAL, NOTE .....................................................1 .............. M150000202 M1550000703 DECAL, AUXILLIARY OUTPUT...........................1 .............. M150000703 M3550000004 DECAL, NOTE .....................................................1 .............. M350000004 M3550000102 DECAL, GENERATOR CONTROL .......................1 .............. M350000105 M3550000202 DECAL, ENGINE OPERATING M35000020 ........1 .............. S/N7500001 TO S/N7500507

M3550000212 DECAL, ENGINE OPERATING M35000020 ........1 .............. S/N7500508~6 M9500000004 DECAL, OIL DRAIN PLUG ..................................1 .............. M900000007 M9500100004 DECAL, WATER...................................................1 .............. M900100008 M9500100104 DECAL, WATER DRAIN PLUG, M90010010 .......1 .............. S/N7500001 TO 75003079 M9500300004 DECAL, - .............................................................1 .............. M9003000010 M9500300104 DECAL, + ............................................................1 .............. M90050000011 M9500500004 DECAL, DIESEL FUEL .......................................1 .............. M9005000012 M9500500104 DECAL, FUEL DRAIN PLUG ...............................1 .............. M9005001013 M9503000004 DECAL, WARNING ..............................................1 .............. M903000014 M9503000103 DECAL, WATER/OIL CHECK ...............................1 .............. M9031001015 M9503100004 DECAL, WARNING ..............................................1 .............. M9031000016 M9503200004 DECAL, WARNING ..............................................1 .............. M9032000017 M9510100004 DECAL, CAUTION ...............................................1 .............. M9101000018 M9510200002 DECAL, MQ .........................................................1 .............. M9102000019 M9520000004 DECAL, GROUND ...............................................1 .............. M9200000020 M9520000104 DECAL, AMMETER CHANGE-OVER SW. ..........1 .............. M9200001021 M9520000204 DECAL, VOLTMETER CHANGE-OVER SW. .......1 .............. M9200002022 M9520100004 DECAL, WARNING ..............................................2 .............. M9201000023 M9520100204 DECAL, CAUTION ...............................................1 .............. M92010020A24 M9520100304 DECAL, SAFETY INSTRUCTIONS .....................1 .............. M9201003025 M9520100404 DECAL, DANGER................................................1 .............. M9201004026 M9520100503 DECAL, WARNING ..............................................1 .............. M9201005027 M9520200003 DECAL, CONNECTION OF OUTPUT CABLE ....1 .............. M9202001028 M9520200104 DECAL, OVER CURRENT RELAY ......................1 .............. M9202001029 M9560100003 STRIPE, WHISPERWATT 130 M3560100103 STRIPE, MQ POWER 231 M3560100203 STRIPE 232 M3560100404 STRIPE 233 M3560100303 STRIPE, 125 134 M3650100503 STRIPE, 125 135 M3650100604 STRIPE 336 M0600500090 EMBLEM 137 0021106015 MACHINE SCREW 238 M3552000103 DECAL, OPERATING PROC., M35200010 .........1 .............. S/N7500508~39 B152000103 DECAL, CAUTION, B15200010 ...........................2 .............. S/N7500508~40 C95053000004 DECAL, CAUTION, C90530000 ...........................1 .............. S/N7500508~41 9039209064 DECAL, START CONTACT, S-4468 .....................1 .............. S/N7500508~42 TBD DECAL, FUELING PROCEDURE........................1


DCA-125SSJU SERIES — GENERATOR ASSY.

GENERATOR ASSY.


DCA-125SSJU SERIES — GENERATOR ASSY.

GENERATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS1 C0110000002 ROTOR ASSY. 11-1 FIELD ASSY. 11-2 8131070013 FAN 11-3 8131611014 COUPLING DISK 81-4 8131015003 BALANCING PLATE 11-5 0012112035 HEX. HEAD BOLT 101-6 0042612000 LOCK WASHER 101-7 8101026013 SET PLATE 11-8 0601821349 RECTIFIER .................................................2 ............ PT36101-9 0601822601 SURGE ABSORBER ...................................1 ............ ERZM14JK621A1-10 8001020004 INSULATOR WASHER 11-11 8001020504 INSULATOR WASHER 11-12 0010110020 HEX. HEAD BOLT 41-13 0040010000 LOCK WASHER 41-14 0601000209 BALANCING WEIGHT KIT 11-15 0071906312 BEARING ....................................................1 ............ 6312 DDU C32 8131340213 STRATOR ASSY. 13 0845041804 GROMMET 24 8131315202 END BRACKET 15 8101350013 FIELD ASSY. EXCITER 16 0012110060 HEX. HEAD BOLT 47 0042610000 LOCK WASHER 48 031110160 PLAIN WASHER ..........................................4 ............ REPLACES 00412100009 0010112035 HEX. HEAD BOLT 610 0040012000 LOCK WASHER 611 031112230 PLAIN WASHER ..........................................6 ............ REPLACES 004121200012 8131310104 COVER, BEARING 113 8131312204 GASKET, BEARING 114 8131331003 COVER, END BRACKET 115 0105050616 HEX. HEAD BOLT .....................................10 ............ REPLACES 0017106012


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

GENERATOR ASSY. (CONT.)


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

GENERATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS16 8101333003 COVER, END BRACKET 117 0010106030 HEX. HEAD BOLT 218 0040006000 LOCK WASHER 219 952404470 PLAIN WASHER ............................... 2 ......... REPLACES 004120600020 M3163400003 COUPLING RING 121 0013904044 HEX. HEAD BOLT ............................ 8 ......... S/N 7500001 TO 750024221 0343204150 HEX. HEAD BOLT ............................ 8 ......... S/N 7500243~22 EM923344 LOCK WASHER ................................ 8 ......... REPLACES 004360400023 0070506306 BEARING ......................................... 1 ......... 6306ZZ24 0012810030 HEX. HEAD BOLT 1225 0012810030 HEX. HEAD BOLT .......................... 12 ......... S/N 7500001 TO 750024225 0010310035 HEX. HEAD BOLT .......................... 12 ......... S/N 7500243~26 0042510000 LOCK WASHER .............................. 12 ......... S/N 7500001 TO 750024227 8131332003 COVER, FAN .................................... 1 ......... S/N 7500001 TO 750024227 8131332014 COVER, FAN .................................... 1 ......... S/N 7500243~28 0605000063 RUBBER SUSPENSION 229 00300165000 HEX. NUT 229 0040016000 LOCK WASHER 230 020106050 NUT .................................................. 1 ......... REPLACES 0600815000

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


CONTROL BOX ASSY.

DCA-125SSJU SERIES — CONTROL BOX ASSY.


CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M3213000102 CONTROL BOX .................................................. 1 ........... S/N 7500001 TO 75000481 M3213000112 CONTROL BOX .................................................. 1 ........... S/N 7500049 TO 75002221 M3213000122 CONTROL BOX .................................................. 1 ........... S/N 7500223 TO 75005071 M3213000132 CONTROL BOX .................................................. 1 ........... S/N 7500508~2 0601808813 CIRCUIT BREAKER ........................................... 1 ........... LAF363001021 3P 300A3 0021006080 MACHINE SCREW 44 0601823863 RELAY UNIT....................................................... 2 ........... MSA9013A5 0021304015 MACHINE SCREW ............................................. 4 ........... REPLACES 00271040156 0601820671 AUTOMATIC VOLTAGE REGULATOR ................. 1 ........... NTA5A2DB7 0027105010 MACHINE SCREW ............................................. 4 ........... S/N 7500001 TO 75002227 0027105015 MACHINE SCREW ............................................. 4 ........... S/N 7500223~8 0601806118 CURRENT TRANSFORMER ............................. 3 ........... 814943 200/5A9 011808015 MACHINE SCREW ............................................. 6 ........... REPLACES 002710601510 0601820845 OVER CURRENT RELAY ................................... 1 ........... LR2D130811 0601820846 OVER CURRENT RELAY ................................... 1 ........... LA7D106412 M1260600004 FITTING BRACKET ........................................... 1 ........... S/N 7500001 TO 750022213 0021304015 MACHINE SCREW ............................................. 2 ........... REPLACES 002710401513 0030004000 HEX. NUT ........................................................... 2 ........... REPLACES 020700400014 0027105020 MACHINE SCREW 415 M3213500003 CONTROL BOX COVER..................................... 1 ........... S/N 7500001 TO 750004815 M3213500013 CONTROL BOX COVER..................................... 1 ........... S/N 7500049~16 011106015 HEX. HEAD BOLT .............................................. 4 ........... REPLACES 001690601517 M3923100004 SELECTOR SWITCH ......................................... 1 ........... VY12517A 47230107 KNOB, SELECTOR SWITCH 118 M3276600004 SPACER 819 M3213600003 SWITCH BRACKET 120 0330000295 EDGING 221 M3260500004 SWITCH BOARD 122 0020004010 MACHINE SCREW ............................................. 4 ........... REPLACES 002110401023 011106015 HEX. HEAD BOLT .............................................. 6 ........... REPLACES 001690601524 M3213600114 SWITCH COVER ................................................ 1 ........... REPLACES M321360010425 011106015 HEX. HEAD BOLT .............................................. 4 ........... REPLACES 001690601526 011106015 HEX. HEAD BOLT ............................................ 10 ........... REPLACES 001690601526 0040506000 TOOTHED WASHER 127 M3223000103 CONTROL PANEL 128 0601807630 FREQUENCY METER,264250DJDJ9 ................ 1 ........... S/N 7500001 TO 750084228 0601807641 FREQUENCY METER,FCF-6 45-65HZ 240V ..... 1 ........... S/N 7500843~

DCA-125SSJU SERIES — CONTROL BOX ASSY.


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

CONTROL BOX ASSY. (CONT.)


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

CONTROL BOX ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS29 0601808953 AC AMMETER, 260240LSLS1JCA .............1 ............ S/N 7500001 TO 750084229 0601808988 AC AMMETER, ACF-6 - 200A,0-400A/5A ...1 ............ S/N 7500843~30 0601801040 CHANGE-OVER SWITCH, AMMETER .......1 ............ SL2AS31 0601806813 AC VOLTMETER, 260244SJSJ1 .................1 ............ S/N 7500001 TO 750084231 0601806859 AC AMMETER, SCF-6 0-600V ....................1 ............ S/N 7500843~32 0601801041 CHANGE-OVER SWITCH, VOLTMETER ....1 ............ SL2VS33 0601840073 RHEOSTAT (VOLTAGE REGULATOR) .........1 ............ RA20A2SE102BJ 2W 1K OHM34 0601840121 KNOB 135 M122310004 STOPPER 136 0027105015 MACHINE SCREW 237 0027105015 MACHINE SCREW 138 M9220100004 SET SCREW 139 0080200007 SNAP RING 140 0601823240 RECTIFER...................................................1 ............ DE450341 0027104020 MACHINE SCREW ......................................1 ............ S/N 7500001 TO 750030741 0027105020 MACHINE SCREW ......................................1 ............ S/N 7500308 TO 750050741 0027104020 MACHINE SCREW ......................................1 ............ S/N 7500508~42 0602200478 EMERGENCY RELAY, 10701606023 ..........1 ............ S/N 7500001 TO 750050743 0027105040 MACHINE SCREW ......................................2 ............ S/N 7500001 TO 750050744 0602202592 STARTER RELAY........................................1 ............ AT14101145 011808015 MACHINE SCREW ......................................2 ............ REPLACES 002710601546 0601823240 RECTIFER, DE4503 ....................................1 ............ S/N 7500508~47 DYN110794000012 CONTROLLER.............................................1 ............ REPLACES 0602202599

................................................................................... S/N 7500508~47 MPS6724 SPEED SENSOR, MAGNETIC PICK UP ...1 ............ REPLACES 060212048548 0027105015 MACHINE SCREW ......................................4 ............ S/N 7500508~49 0601823768 RELAY, LY2US12VD ....................................1 ............ S/N 7500508 TO 750054249 LY2US12VDC RELAY .........................................................1 ............ REPLACES 0601827656

................................................................................... S/N 7500543~49 PTF08AE BASE, RELAY SOCKET .............................1 ............ REPLACES 0601823109

................................................................................... S/N 7500508~49 PYCA1 CLIP ............................................................2 ............ REPLACES 0601824400

................................................................................... S/N 7500508~50 0601823223 RECTIFER...................................................1 ............ 30D4 S/N 7500508 TO 750054251 0027104020 MACHINE SCREW ......................................2 ............ S/N 7500508~52 M3246700304 WIRE HARNESS, GENERATOR 1


DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.


DCA-125SSJU SERIES — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS1 M3923200004 ENGINE .............................................. 1 .................JOHN DEERE 6068TF1-1 0602041290 ELEMENT, OIL FILTER ...................... 1 .................RE59754A1-2 0602042590 ELEMENT, FUEL FILTER .................. 1 .................RE624181-3 0602014297 ELECTRIC HEATER........................... 1 .................RE296581-3 RE502668 ELECTRIC HEATER ASSY. .....................................S/N 7500263-2 0602060010 BLOWER FAN .................................... 1 .................4221983 0602061000 FAN SPACER ...................................... 1 .................R819114 0012110090 HEX. HEAD BOLT ............................... 4 .................S/N 7500001 TO 75000034 0012110095 HEX. HEAD BOLT 45 030210250 LOCK WASHER ................................. 4 .................REPLACES 00425100006 M2303200303 ENGINE FOOT 27 0131151240 HEX HEAD BOLT ............................... 6 .................REPLACES 00103120308 0040012000 LOCK WASHER 69 0605000060 RUBBER SUSPENSION 210 0030012000 HEX. NUT 211 0040012000 LOCK WASHER 212 0602011988 RADIATOR, RE52824 ........................ 1 .................S/N 7500001 TO 750000312 0602012723 RADIATOR, C2810060000 ................ 1 .................S/N 7500308 TO 750095212 0602012747 RADIATOR, C281-009-003 ................ 1 .................S/N 750095312-1 0602011067 CAP ..................................................... 1 .................S/N 7500001 TO 750030712-1 0602011066 CAP ..................................................... 1 .................S/N 7500308~12-2 0199101200 HOSE .................................................. 1 .................S/N 7500308~13 0602010795 FAN COVER, C2810044210 .............. 1 .................S/N 7500001 TO 750030714 0013006008 HEX. HEAD BOLT ............................... 8 .................S/N 7500001 TO 750030715 0043106000 PLAIN WASHER ................................. 8 .................S/N 7500001 TO 750030716 M3310200204 RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 750030717 M3310200404 RADIATOR BRACKET ....................... 1 .................S/N 7500001 TO 750030718 0013006008 S/N 7500001 TO 7500307 ................. 8 .................S/N 7500001 TO 750030719 0043006000 LOCK WASHER ................................. 8 .................S/N 7500001 TO 750030720 0043106000 PLAIN WASHER ................................. 8 .................S/N 7500001 TO 750030721 011008020 HEX HEAD BOLT ............................... 8 .................REPLACES 00169082022 0468102000 PLUG .................................................. 1 .................S/N 7500001 TO 750030723 M3310500003 RADIATOR HOSE, UPPER ................ 1 .................S/N 7500001 TO 750030723 M3310500403 RADIATOR HOSE, UPPER ................ 1 .................S/N 7500308~24 M3310500103 RADIATOR HOSE, LOWER............... 1 .................S/N 7500001 TO 750030724 M3310500503 RADIATOR HOSE, LOWER............... 1 .................S/N 7500308~25 0605515148 HOSE BAND 226 0605515147 HOSE BAND 227 0605512190 HOSE JOINT 128 M2320300103 DRAIN JOINT ..................................... 1 .................S/N 7500001 TO 750030729 M9200200004 DRAIN BOLT ....................................... 1 .................S/N 7500001 TO 750030730 0150000018 O RING ............................................... 1 .................S/N 7500001 TO 750030731 0016906020 HEX HEAD BOLT ............................... 2 .................S/N 7500001 TO 750030732 0191300580 DRAIN HOSE ...................................... 1 .................S/N 7500001 TO 750030733 0605515189 HOSE BAND ....................................... 2 .................S/N 7500001 TO 750030734 0602046258 AIR CLEANER .................................... 1 .................FRG10029734 0602046377 ELEMENT, AIR CLEANER ................. 1 .................P77821435 0602040650 INDICATOR, AIR CLEANER .............. 1 .................RBX00225236 0603306385 NIPPLE ................................................ 1 .................S/N 7500001 TO 750000437 0602040596 BAND, AIR CLEANER ........................ 1 .................P00407638 011008020 HEX. HEAD BOLT ............................... 4 .................REPLACES 001690802039 020108060 HEX, NUT ........................................... 4 .................REPLACES 020700800040 M337310003 HOSE, AIR CLEANER 141 0605515146 HOSE BAND ....................................... 1 .................503542 0605515200 HOSE BAND ....................................... 1 .................507243 0602022563 ADAPTER 1


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

ENGINE AND RADIATOR ASSY. (CONT.)


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

ENGINE AND RADIATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS44 0602021165 O-RING .......................................... 1 ........... S/N 7500001 TO 750030745 0602022561 90o ELBOW .................................... 1 ........... 3398210-10+46 0602022562 UNION, 10WTXWLNS.................... 1 ........... S/N 7500001 TO 750030747 0602022792 SWIVEL, 306821010 ...................... 1 ........... S/N 7500001 TO 750030748 0602021070 CAP ............................................... 1 ........... 10FNTXS49 0602021573 DRAIN HOSE ................................. 1 ........... 83610 S/N 7500001 TO 750030749 0269200406 DRAIN HOSE ................................. 1 ........... 83610 S/N 7500263~50 M9300000203 RESERVE TANK 151 06020100900 CAP, RESERVE TANK 152 M3316100104 BRACKET, RESERVE TANK 153 0110080020 HEX.HEAD BOLT .......................... 2 ........... REPLACES 001690802054 0193601080 HOSE 155 M2260600024 RELAY BRACKET 156 0602202597 RELAY, AL64309 ............................ 1 ........... S/N 7500001 TO 750026256 0602202592 RELAY, AT141011 .......................... 1 ........... S/N 7500263~57 0017106015 HEX. HEAD BOLT .......................... 1 ........... S/N 7500001 TO 750026257 011808015 MACHINE SCREW ........................ 2 ........... REPL. 0027106015 S/N 7500263~58 M3313100004 RADIATOR COVER ........................ 1 ........... S/N 7500001 TO 750030758 M3313100204 RADIATOR COVER ........................ 1 ........... S/N 7500508~59 0110080020 HEX. HEAD BOLT .......................... 4 ........... REPLACES 001690802060 0043006000 LOCK WASHER ............................. 8 ........... S/N 7500001 TO 750030761 0110080020 HEX. HEAD BOLT .......................... 1 ........... REPLACES 001690802062 0602122281 OIL SWITCH .................................. 1 ........... 171893901163 0602123282 WATER SWITCH ............................ 1 ........... 151818304164 M9200100404 ADAPTER 165 M9200100704 ADAPTER ...................................... 1 ........... S/N 7500004~66 0605511395 VALVE, XV500P8 .......................... 1 ........... S/N 7500508~67 DYNC700250000012 ACTUATOR .................................... 1 ........... REPL. 0602150093 S/N 7500508~68 M3356200004 STOPPER BRACKET .................... 1 ........... S/N 7500508~69 0016910015 HEX. HEAD BOLT .......................... 1 ........... REPL. 0017110020 S/N 7500508~70 0016906020 HEX. HEAD BOLT .......................... 1 ........... S/N 7500508~71 0207006000 HEX. NUT ...................................... 1 ........... S/N 7500508~72 0603306590 CONNECTOR, 10WFTXS .............. 1 ........... S/N 7500508~73 0603300285 ROCK UNIT, 10WLN ...................... 1 ........... S/N 7500508~74 0603306395 HOSE JOINT, 30182810 ................ 1 ........... S/N 7500508~75 0602011491 FAN BELT 1


DCA-125SSJU SERIES — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

S/N7500001 TO S/N 7500507

S/N 7500508~


DCA-125SSJU SERIES — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M1354300304 SLIDE LEVER .............................................1 ............ S/N 7500001 TO 75005072 M9320000004 KNOB ..........................................................1 ............ S/N 7500001 TO 75005073 0036003000 HEX. NUT ....................................................1 ............ S/N 7500001 TO 75005074 0605804150 SPRING .......................................................1 ............ S/N 7500001 TO 75005075 0041208000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 75005076 M1354200004 BRACKET ...................................................1 ............ S/N 7500001 TO 75005077 0207008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 75005078 0030008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 75005079 0605010550 SNAP PIN ...................................................1 ............ S/N 7500001 TO 750050710 M3354300104 GOVERNOR ROD .......................................1 ............ S/N 7500001 TO 750050711 0602180106 BALL JOINT, LHSA8DE161 .........................1 ............ S/N 7500001 TO 750050712 0030008000 HEX NUT .....................................................1 ............ S/N 7500001 TO 750050713 0602180107 BALL JOINT, LHSA8DLE161 .......................1 ............ S/N 7500001 TO 750050714 0036508000 HEX NUT .....................................................1 ............ S/N 7500001 TO 750050715 0207006000 HEX NUT .....................................................2 ............ S/N 7500001 TO 750050715 0041206000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 750050716A AR51481 KEY, STARTER SWITCH ............................1 ............ S/N 7500001 TO 750050716 0602100056 STARTER SWITCH, AR58126.....................1 ............ S/N 7500001 TO 750050716 0602100028 SET NUT, R44342 .......................................1 ............ S/N 7500001 TO 750050716 0602100029 SET WASHER, A4827R ..............................1 ............ S/N 7500001 TO 750050717 0601831594 COLD STARTER BUTTON, R39554 ............1 ............ S/N 7500001 TO 750034217 0601831585 COLD STARTER BUTTON ..........................1 ............ S/N 7500343~17 0601831584 CAP, T55585 ................................................1 ............ S/N 7500001 TO 750034217 0601831588 CAP, 44053 ..................................................1 ............ S/N 7500343~18 0602120096 TACHOMETER ............................................1 ............ 10367819 0602122093 OIL PRESSURE GAUGE ............................1 ............ 10017420 0602122272 UNIT, OIL PRESSURE 121 0602123092 WATER TEMPERATURE GAUGE ...............1 ............ 10018222 0602123261 UNIT, WATER TEMPERATURE ...................1 ............ 020250023 0602121080 CHARGING AMMETER ..............................1 ............ 10015824 0602125090 FUEL GAUGE ..............................................1 ............ 10017625 0602103092 ALARM LAMP, PL05....................................2 ............ S/N 7500001 TO 750050725 0601810245 BULB, E10T10 DC18V ................................2 ............ S/N 7500001 TO 750050726 0601810141 PANEL LIGHT ..............................................1 ............ 982680037027 0601831330 SWITCH, PANEL LIGHT..............................1 ............ 90000128 ECU9988NJD ENGINE CONTROLLER ..............................1 ............ REPLACES 060220254529 0027104035 MACHINE SCREW ......................................2 ............ S/N 7500508~29 0030000400 HEX. NUT ....................................................2 ............ REPL. 0207004000 S/N 7500508~30 0601831340 SWITCH, 7562K4 ........................................1 ............ S/N 7500508~30 0600500091 NAME PLATE ..............................................1 ............ S/N 7500508~31 0601831395 SWITCH, 7302K36 ......................................1 ............ S/N 7500508~32 M3357200002 WIRE HARNESS, ENGINE .........................1 ............ S/N 7500001 TO 750026232 M3357200012 WIRE HARNESS, ENGINE .........................1 ............ S/N7500263 TO 750050732 M3359200302 WIRE HARNESS, ENGINE .........................1 ............ S/N7500508~


DCA-125SSJU SERIES — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.


DCA-125SSJU SERIES — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M3230700003 TERMINAL PANEL 12 M9220100304 OUTPUT TERMINAL BOLT 53 M9220100404 TIE BOLT 54 0039316000 HEX. NUT 105 0040016000 LOCK WASHER 156 0041416000 PLAIN WASHER 207 0012108035 HEX. HEAD BOLT .................................... 5 .............. REPLACES 00169080358 M3236100303 TERMINAL COVER .................................. 1 .............. S/N 7500001 TO 75003078 M3236100313 TERMINAL COVER .................................. 1 .............. S/N7500308 TO S/N75005078 M3238100103 TERMINAL COVER .................................. 1 .............. S/N7500508~9 M3236100104 OUTPUT WINDOW 110 0605010040 HINGE 211 0027103010 MACHINE SCREW 411 0207003000 HEX. NUT ................................................. 4 .............. REPLACES 003000300011 0041203000 PLAIN WASHER 412 0027103010 MACHINE SCREW 412 0207003000 HEX. NUT ................................................. 4 .............. REPLACES 003000300013 011206020 HEX. HEAD BOLT .................................... 2 .............. REPLACES 001690602014 0016906015 HEX. HEAD BOLT 415 M2236400004 CABLE OUTLET COVER ......................... 1 .............. S/N 7500001 TO 750003415 M3236400004 CABLE OUTLET COVER ......................... 1 .............. S/N 7500035~16 M2236300004 SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500001 TO 750003416 M3236300004 SUPPORTER,CABLE OUTLET COVER .. 1 .............. S/N 7500035~17 011206020 HEX. HEAD BOLT .................................... 6 .............. REPLACES 001690602018 0601808803 CIRCUIT BREAKER ................................. 2 .............. Q0U 120B 1P 20A19 0601808804 CIRCUIT BREAKER ................................. 3 .............. Q0U 250B 2P 50A20 M1260700304 BREAKER FITTING COVER 120-1 0222100150 CUSHION RUBBER 121 011206020 HEX. HEAD BOLT .................................... 2 .............. REPLACES 001690602022 0601812597 RECEPTACLE, GF530EM 125V 20AX2 ... 2 .............. REPLACES 060181259823 0601811034 RECEPTACLE, CS6369 250V 50A ........... 3 .............. REPLACES 060181253824 0021304015 MACHINE SCREW ................................. 10 .............. REPLACES 002710401524 0030004000 HEX. NUT ............................................... 10 .............. REPLACES 020700400025 M3236100203 TERMINAL COVER .................................. 1 .............. S/N 7500001 TO 750003425 M3236100213 TERMINAL COVER .................................. 1 .............. S/N 7500035~26 012212045 HEX. HEAD BOLT .................................... 2 .............. REPLACES 001011204527 031112230 PLAIN WASHER 228 M9310200004 STAY RUBBER 229 0030012000 NUT 230 M2354200004 SUPPORTER, GOVERNOR ROD ............ 1 .............. S/N 7500001 TO 750050731 0016906015 HEX. HEAD BOLT .................................... 2 .............. S/N 7500001 TO 750050732 M3455600004 PLUG ........................................................ 2 .............. S/N 7500508~32 0603306775 PLUG ........................................................ 2 .............. S/N 7500508~33 0021304015 MACHINE SCREW ................................... 4 .............. REPLACES 0027104015

................................................................................... S/N 7500508~34 0601815194 TERMINAL, 6041GP02 ............................ 1 .............. S/N 7500508~35 0021304015 MACHINE SCREW ................................... 2 .............. REPL. 0027104015 S/N 7500508~


DCA-125SSJU SERIES — BATTERY ASSY.

BATTERY ASSY.


DCA-125SSJU SERIES — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 0602220196 BATTERY ....................................................1 ............ 4D-22 M9310500404 BATTERY SHEET 13 M9103000504 BATTERY BAND 14 0602220921 BATTERY BOLT SET 25 0040006000 LOCK WASHER 26 M3346900004 BATTERY CABLE 17 M3346900104 BATTERY CABLE 18 CABLE .........................................................1 ............ MAKE LOCALLY9 0017112025 HEX. HEAD BOLT 19 0040512000 TOOTHED WASHER 110 0017110020 HEX. HEAD BOLT 110 0040510000 TOOTHED WASHER 1


DCA-125SSJU SERIES — MUFFLER ASSY.

MUFFLER ASSY.


10 0602326061 U BOLT SET 1 89547K

DCA-125SSJU SERIES — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M3330100002 MUFFLER ....................................................1 ............ S/N 7500001 TO 75000721 0602300167 MUFFLER ....................................................1 ............ S/N 7500073~2 012210025 HEX. HEAD BOLT .......................................4 ............ REPLACES 00169100253 M3333000303 EXHAUST PIPE 14 0602325066 CLAMP 15 M3333200004 GASKET 16 014210040 HEX. HEAD BOLT .......................................4 ............ REPLACES 00171100407 M33330400304 COVER 18 M3330400403 BRACKET 19 011008020 HEX. HEAD BOLT .......................................4 ............ REPLACES 001690802010 0602326061 U-BOLT SET................................................1 ............ 89547K


DCA-125SSJU SERIES — FUEL TANK ASSY.

FUEL TANK ASSY.


DCA-125SSJU SERIES — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M3363000202 FUEL TANK 11-1 0605505070 CAP, FUEL TANK 12 M3363200204 TANK BAND 23 M9310500104 SUPPORTERsheet 44 0016908020 HEX. HEAD BOLT 25 037908000 HEX NUT .....................................................2 ............ S/N 7500001 TO 75000345 0207308000 HEX NUT .....................................................2 ............ S/N 7500035~5 0041208000 PLAIN WASHER ..........................................2 ............ S/N 7500001 TO 75000346 0222100660 RUBBER SHEET 27 M9200000003 DRAIN JOINT 18 M9200200004 DRAIN BOLT 19 0150000018 O RING ........................................................1 ............ AP1810 0016906020 HEX. HEAD BOLT 211 M1363400104 DRAIN HOSE 112 0605515198 HOSE BAND ...............................................2 ............ 500813 0602042420 FUEL FILTER ..............................................1 ............ PTG15P14 0602042601 LEAK-OFF LINE ..........................................1 ............ RE6705015 0191300450 SUCTION HOSE 116 0191301802 SUCTION HOSE 117 0191302200 RETURN HOSE 118 0605515189 HOSE BAND ...............................................1 ............ 9100419 0605515109 HOSE BAND ...............................................5 ............ RS801020 0602220911 CLAMP ........................................................1 ............ RCT2010


DCA-125SSJU SERIES — ENCLOSURE ASSY.

ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATECOLOR OF UNIT:1-ORANGE2-WHITE3 -SPECTRUM GRAY4 -SUNBELT GREEN

5 -BLACK6 -CATERPILLAR YELLOW7 -CATO GOLD

THE SERIAL NUMBER MAY BE REQUIRED.


DCA-125SSJU SERIES — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 M3413000102 BASE ................................................ 1 ........... S/N 7500001 TO 75003071 M3413000112 BASE ................................................ 1 ........... S/N 7500308 TO S/N75005071 M3413000122 BASE ................................................ 1 ........... S/N7500508~2 M1413400004 UNDER COVER 13 012210025 HEX. HEAD BOLT ............................. 2 ........... REPLACES 00169100254 M3423000302 FRONT FRAME ................................. 1 ........... S/N 7500001 TO S/N 75003074 M3423000602 FRONT FRAME ................................. 1 ........... S/N7500308~4 M3493100203 ACOUSTIC SHEET ........................... 1 ........... S/N7500283 TO S/N75003074 M3493100503 ACOUSTIC SHEET ........................... 1 ........... S/N7500308~5 012210025 HEX. HEAD BOLT ............................. 6 ........... REPLACES 00169100256 M3423200104 COVER, FRONT FRAME 16 M3493100304 ACOUSTIC SHEET 17 011008020 HEX. HEAD BOLT ........................... 14 ........... REPLACES 00169080208 M3433000102 CENTER FRAME 18 M3493200004 ACOUSTIC SHEET 19 0010114040 HEX. HEAD BOLT 129 0030014000 HEX. NUT 129 0040014000 LOCK WASHER 249 031114260 PLAIN WASHER .............................. 24 ........... REPLACES 004121400010 M3443000202 REAR FRAME ................................... 1 ........... S/N 7500001 TO S/N 750050710 M3443000212 REAR FRAME ................................... 1 ........... S/N7500508~10 M3493300204 ACOUSTIC SHEET 111 012210025 HEX. HEAD BOLT ............................. 4 ........... REPLACES 001691002512 M3443300203 REAR COVER 113 M3443300303 DUCT, REAR COVER 113 M3493300303 ACOUSTIC SHEET 114 0207006000 HEX. NUT 1215 011008020 HEX. HEAD BOLT ........................... 10 ........... REPLACES 001690802016 M3443200103 REAR DOOR ..................................... 1 ........... S/N 7500001 TO S/N 750014816 M3443200113 REAR DOOR ..................................... 1 ........... S/N 7500149~17 M3443600104 WINDOW PLATE ............................... 118 0037906000 HEX. NUT ........................................ 10 ........... S/N 7500001 TO S/N 750003418 020106050 HEX. NUT ........................................ 10 ........... REPLACES 0207306000

......................................................................... S/N 7500035~18 0041206000 PLAIN WASHER .............................. 10 ........... S/N 7500035~18 0041206000 PLAIN WASHER .............................. 20 ........... S/N 7500001 TO S/N 750003419 B9114000002 DOOR HANDLE ASSY. 120 0027106016 MACHINE SCREW ............................ 4 ........... REPLACES 002180601520 020106050 HEX. NUT .......................................... 4 ........... REPLACES 003000600021 M9110100204 HINGE 222 M9116100004 WASHER 223 011008020 HEX. HEAD BOLT ............................. 3 ........... REPLACES 001690802024 M9310000004 BLIND PLUG 2


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

ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATECOLOR OF UNIT:1-ORANGE2-WHITE3 -SPECTRUM GRAY4 -SUNBELT GREEN

5 -BLACK6 -CATERPILLAR YELLOW7 -CATO GOLD

THE SERIAL NUMBER MAY BE REQUIRED.


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

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS25 M3463100203 ROOF PANEL 125 M3493500203 ACOUSTIC SHEET 126 M3463200102 ROOF PANEL 126 M3493500303 ACOUSTIC SHEET 127 M3463500104 OVER COVER, FRONT FRAME 128 011008020 HEX. HEAD BOLT ....................................37 ............. REPLACES 001690802029 M9310000103 ENCLOSURE CAP 130 M1483600204 CHAIN ASSY. 131 M3453200102 SPLASHER PANEL ................................... 1 ............. S/N 7500001 TO S/N 750003431 M3453200102 SPLASHER PANEL ................................... 1 ............. S/N 7500035 TO S/N750030731 M3453200122 SPLASHER PANEL ................................... 1 ............. S/N 7500308 TO S/N750050731 M3453200132 SPLASHER PANEL ................................... 1 ............. S/N7500508~31 M3493401304 ACOUSTIC SHEET 1 ............. S/N 7500001 TO S/N 750003431 M3493401314 ACOUSTIC SHEET 1 ............. S/N 7500035~32 011208060 HEX. HEAD BOLT ..................................... 4 ............. REPLACES 001690805533 012210025 HEX. HEAD BOLT ..................................... 2 ............. REPLACES 001691002534 M3453000703 SIDE DOOR 134 M3493400704 ACOUSTIC KIT A.S. FRONT DOOR (L) 135 M3453000603 SIDE DOOR 135 M3453400804 ACOUSTIC SHEET 136 M3453000503 SIDE DOOR (L) 136 M3493401004 ACOUSTIC SHEET (L) 137 M3453000403 SIDE DOOR (R) 137 M3493401104 ACOUSTIC KIT A.S. REAR DOOR (R) 138 M3453300303 DUCT (L) 138 M3493400904 ACOUSTIC KIT A.S. FRONT DUCT (L) 139 M3453300503 DUCT (R FRONT) 139 M3493401404 ACOUSTIC KIT A.S. FRONT DOOR DUCT140 M3453300203 DUCT (R) 140 M3493401204 ACOUSTIC KIT A.S. REAR DOOR DUCT 141 0207006000 HEX. NUT 2542 B9114000002 DOOR HANDLE ASSY. ............................. 4 ............. REPLACES M911300000243 0027106016 MACHINE SCREW ...................................16 ............. REPLACES 002180601543 020106050 HEX. NUT .................................................16 ............. REPLACES 003000600044 M9110100204 HINGE (L) 445 M9110100304 HINGE (R) 446 M9116100004 WASHER 847 011008020 HEX. HEAD BOLT ..................................... 9 ............. REPLACES 001690802048 0601850097 DOOR STOPPER 849 0027208025 MACHINE SCREW 850 0845031504 BLIND PLUG ............................................. 8 ............. REPLACES M931000000451 M3453700004 DOOR BRACKET 152 0016906015 HEX. HEAD BOLT 453 016908020 HEX. HEAD BOLT 153 0040508000 TOOTHED WASHER 1


DCA-125SSJU SERIES — RUBBER SEAL ASSY.

RUBBER SEAL ASSY.


DCA-125SSJU SERIES — RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS1 0228900890 RUBBER SEAL 32 0229200810 RUBBER SEAL 13 0228901020 RUBBER SEAL 24 0228900990 RUBBER SEAL 45 0228900955 RUBBER SEAL 46 0228900470 RUBBER SEAL 27 0228900470 RUBBER SEAL 48 0229201040 RUBBER SEAL 19 0228800970 RUBBER SEAL 210 0228800590 RUBBER SEAL 111 0228800630 RUBBER SEAL 112 0228100665 RUBBER SEAL 113 0228100300 RUBBER SEAL 114 0228100370 RUBBER SEAL 115 0228100280 RUBBER SEAL 116 0228100365 RUBBER SEAL 117 0228100070 RUBBER SEAL 1


Effective: October 1, 2002 TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

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

MINIMUM ORDER

The minimum charge for orders from Multiquipis $15.00 net. Customers will be asked forinstructions regarding handling of orders notmeeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and creditwill be allowed, subject to the following provi-sions:

1. A Returned Material Authorization mustbe approved by Multiquip prior to ship-ment.

2. To obtain a Return Material Authorization,a list must be provided to Multiquip PartsSales that defines item numbers, quanti-ties, and descriptions of the items to bereturned.

a. The parts numbers and descriptionsmust match the current parts pricelist.

b. The list must be typed or computergenerated.

c. The list must state the reason(s) forthe return.

d. The list must reference the salesorder(s) or invoice(s) under which theitems were originally purchased.

e. The list must include the name andphone number of the person request-ing the RMA.

3. A copy of the Return Material Authoriza-tion must accompany the return shipment.

4. Freight is at the sender’s expense. Allparts must be returned freight prepaid toMultiquip’s designated receiving point.

5. Parts must be in new and resalablecondition, in the original Multiquip pack-age (if any), and with Multiquip partnumbers clearly marked.

6. The following items are not returnable:

a. Obsolete parts. (If an item is in theprice book and shows as beingreplaced by another item, it isobsolete.)

b. Any parts with a limited shelf life(such as gaskets, seals, “O” rings,and other rubber parts) that werepurchased more than six monthsprior to the return date.

c. Any line item with an extended dealernet price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of anymaterial received that is not acceptable.

8. Such material will be held for fiveworking days from notification, pendinginstructions. If a reply is not receivedwithin five days, the material will bereturned to the sender at his expense.

9. Credit on returned parts will be issued atdealer net price at time of the originalpurchase, less a 15% restocking charge.

10. In cases where an item is accepted, forwhich the original purchase documentcan not be determined, the price will bebased on the list price that was effectivetwelve months prior to the RMA date.

11. Credit issued will be applied to futurepurchases only.

PRICING AND REBATES

Prices are subject to change without priornotice. Price changes are effective on a spe-cific date and all orders received on or afterthat date will be billed at the revised price.

Rebates for price declines and added chargesfor price increases will not be made for stockon hand at the time of any price change.

Multiquip reserves the right to quote and selldirect to Government agencies, and to OriginalEquipment Manufacturer accounts who useour products as integral parts of their ownproducts.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoicefor special handling including bus shipments,insured parcel post or in cases where Multiquipmust personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under fordamages in excess of the purchase price of theitem with respect to which damages are claimed,and in no event shall Multiquip be liable for lossof profit or good will or for any other special,consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made inconnection with the sale of parts or trade acces-sories nor as to any engine not manufacturedby Multiquip. Such warranties made in connec-tion with the sale of new, complete units aremade exclusively by a statement of warrantypackaged with such units, and Multiquip nei-ther assumes not authorizes any person toassume for it any other obligation or liabilitywhatever in connection with the sale of itsproducts. Apart from such written statement ofwarranty, there are no warranties, express,implied or statutory, which extend beyond thedescription of the products on the face hereof.


NOTE PAGE

MULTIQUIP INC..... PARTS DEPARTMENT:18910 WILMINGTON AVE. 800-427-1244CARSON, CALIFORNIA 90746 FAX: 800-672-7877310-537-3700 SERVICE DEPARTMENT:800-421-1244 800-835-2551FAX: 310-537-3927 FAX: 310-638-8046E-mail:[email protected] www:multiquip.com

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIALNUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT800-427-1244 or 310-537-3700FAX: 800-672-7877 or 310-637-3284

SERVICE DEPARTMENT800-421-1244FAX: 310- 537-4259

TECHNICAL ASSISTANCE800-478-1244FAX: 310- 631-5032

WARRANTY DEPARTMENT888-661-4279, or 310-661-4279FAX: 310- 537-1173

MQ POWER DCA-125SSJU DCA-125SSJU2 PORTABLE · PDF fileCoolant Capacity 10.3 gal. ......

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