PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
®
MODEL DCA125USJ
60 Hz GENERATOR
(JOHN DEERE 6068TF 275 DIESEL ENGINE)
PARTS LIST NO. M3870400004
Revision #2 (01/27/11)
To find the latest revision of this
publication, visit our website at:
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.
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DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 3
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TABLE OF CONTENTS
MQ POWER DCA12USJ
AC GENERATOR
COMPONENT DRAWINGS
Generator Assembly.................................................. 54-55
Control Box Assembly............................................... 56-59
Engine & Radiator Assembly..................................... 60-63
Output Terminal Assembly......................................... 64-65
Battery Assembly ...................................................... 66-67
Muffler Assembly ...................................................... 68-69
Fuel Tank Assembly .................................................. 70-71
Enclosure #1 Assembly ............................................ 72-75
Enclosure #2 Assembly ............................................ 76-77
Rubber Seals Assembly ............................................ 78-79
Nameplate and Decals .............................................. 80-81
California Proposition 65 Warning .....................................2
Here's How To Get Help ....................................................3
Table Of Contents .............................................................4
Parts Ordering Procedures ...............................................5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) .......................................... 7
Safety Information ....................................................... 8-13
Generator Decals....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 21
Engine Operating Panel ............................................. 22-23
OutputTerminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
OutputTerminal Panel Connections ........................... 30-31
Pre Setup .................................................................. 32-35
Generator Start-up Procedure (Manual) ..................... 36-37
Generator Start-up Procedure (Auto Mode) .................... 38
Generator Shut-Down Procedure .................................... 39
Maintenance .............................................................. 40-42
Trailer Brakes Maintenance ............................................ 43
Trailer Maintenance.................................................... 44-45
TrailerWiring Diagram ..................................................... 46
Generator Wiring Diagram ............................................... 47
Engine Wiring Diagram ................................................... 48
GeneratorTroubleshooting .............................................. 49
Engine ControllerTroubleshooting ................................... 50
Explanation of Code in Remarks Column ....................... 52
Suggested Spare Parts .................................................. 53
Terms and Condition of Sale — Parts ............................ 82
Specification and part
number are subject to
NOTE
change without notice.
PAGE 4 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
Order via Phone:
1-800-427-1244
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
❒
Dealer Account Number
❒
Specify Preferred Method of Shipment:
❒
❒
❒
❒
❒
Dealer Name and Address
✓ UPS/Fed Ex
✓ DHL
✓ Truck
■
■
Priority One
Ground
Shipping Address (if different than billing address)
Return Fax Number
■ Next Day
Second/Third Day
Applicable Model Number
■
Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
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DCA-125USJ — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA125USJ
Revolving field, self ventilated, open protected type synchronous
generator
Armature Connection
Phase
Star with Neutral
3
Zig Zag
Single
Standby Output
Prime Output
Voltage
137 KVA (110 KW)
125 KVA (100 KW)
240V or 480V
79 KW
72 KW
240/120V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
1
Single Phase, 60 Hz
120 V
Output
4.8 KW (2.4 KW x 2)
Table 2. Engine Specifications
Model
Type
JOHN DEERE 6068TF 275
4 cycle, water-cooled, direct injection, turbo-charged
6 cylinders
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
4.19 in. x 5 in. (106 mm x 127 mm)
150 HP/1800 rpm
415 cu. in. (6,800 cc)
Electric 12VDC
Coolant Capacity
Lube Oil Capacity
Fuel Type
4.4 gal. (16.8 liters)
5.3 gal. (18.9 liters)
#2 Diesel Fuel
Fuel Tank Capacity
169 gal. (640 liters)
7.7 gal. (29.0 L)/hr at full load
3.8 gal. (14.5 L)/hr at 1/2 load
5.8 gal. (21.9 L)/hr at 3/4 load
Fuel Consumption
Battery
2.5 gal. (9.3 L)/hr at 1/4 load
12V BCI Group 46
PAGE 6 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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DCA-125USJ — SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual.Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER,WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 8 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — SAFETY INFORMATION
„ NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
GENERAL SAFETY
CAUTION
„ NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
„ ALWAYS know the location of the nearest
fire extinguisher.
„ ALWAYS know the location of the nearest
first aid kit.
„ ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
„ NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
„ NEVER operate this equipment under the influence of
drugs or alcohol.
GENERATOR SAFETY
DANGER
„ NEVER operate the equipment in an explosive
atmosphere or near combustible materials.An
explosion or fire could result causing severe
bodily harm or even death.
„ ALWAYS check the equipment for loosened threads or
bolts before starting.
„ DO NOT use the equipment for any purpose other than
its intended purposes or applications.
WARNING
„ NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death.Disconnection of any of these
devices will void all warranties.
NOTICE
„ This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
„ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
CAUTION
„ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
„ NEVER lubricate components or attempt service on a
running machine.
NOTICE
„ ALWAYS ensure generator is on level ground before use.
„ ALWAYS keep the machine in proper running condition.
„ Fix damage to machine and replace any broken parts
immediately.
„ ALWAYS store equipment properly when it is not being
used.Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
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DCA-125USJ — SAFETY INFORMATION
ENGINE SAFETY
DANGER
NOTICE
„ NEVER run engine without an air filter or with a dirty air
filter.Severe engine damage may occur.Service air filter
frequently to prevent engine malfunction.
„ The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
„ NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
„ The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
„ Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied.When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
WARNING
„ DO NOT place hands or fingers inside engine
compartment when engine is running.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
„ NEVER operate the engine with heat shields or
guards removed.
„ Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition.It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
„ DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
„ DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
hours to burn off the accumulated unburned fuel.
„ State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels.A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
„ DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
„ NEVER touch the hot exhaust manifold,
muffler or cylinder.Allow these parts to cool
before servicing equipment.
PAGE 10 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — SAFETY INFORMATION
„ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
FUEL SAFETY
DANGER
„ DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
„ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
„ Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
„ ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
„ ALWAYS use extreme caution when working with
flammable liquids.
„ ALWAYS make sure the trailer is equipped with a safety
chain.
„ DO NOT fill the fuel tank while the engine is running
or hot.
„ ALWAYS properly attach trailer’s safety chains to towing
vehicle.
„ DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
„ ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
„ Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
„ DOT Requirements include the following:
s #ONNECT ANDTEST ELECTRICBRAKEOPERATIONꢀ
„ NEVER use fuel as a cleaning agent.
s 3ECURE PORTABLE POWER CABLES IN CABLE TRAY WITH TIE
wraps.
„ DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
„ The maximum speed for highway towing is 55 MPH unless
posted otherwise.Recommended off-road towing is not to
exceed 15 MPH or less depending on type of terrain.
TOWING SAFETY
CAUTION
„ Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
„ Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations, before towing
your generator.
„ Avoid sharp turns to prevent rolling.
„ Trailer should be adjusted to a level position at all times
when towing.
„ Raise and lock trailer wheel stand in up position when
towing.
„ Refer to MQ Power trailer manual for additional safety
information.
„ Place chock blocks underneath wheel to prevent rolling
while parked.
„ In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
„ Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
„ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
„ ALWAYS shutdown engine before transporting
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DCA-125USJ — SAFETY INFORMATION
„ Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
ELECTRICAL SAFETY
DANGER
„ DO NOT touch output terminals during
operation. Contact with output terminals
duringoperationcancause electrocution,
electrical shock or burn.
NOTICE
„ ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
„ The electrical voltage required to
operate the generator can cause severe
Grounding Safety
DANGER
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
„ ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
„ NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous.The possibility exists
of electrical shock, electrocution or
death.
„ NEVER use gas piping as an electrical ground.
„ Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Power Cord/Cable Safety
DANGER
„ NEVER let power cords or cables lay in water.
„ NEVER stand in water while AC power from the
generator is being transferred to a load.
„ NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
„ NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 12 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — SAFETY INFORMATION
BATTERY SAFETY
DANGER
ENVIRONMENTAL SAFETY
NOTICE
„ DO NOT drop the battery.There is a possibility that the
battery will explode.
„ Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
„ DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
„ DO NOT use food or plastic containers to
dispose of hazardous waste.
„ DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
WARNING
„ ALWAYS wear safety glasses when handling
the battery to avoid eye irritation.The battery
contains acids that can cause injury to the
eyes and skin.
„ Use well-insulated gloves when picking up the battery.
„ ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
„ ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
„ ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
„ ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
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DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 13
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DCA-125USJ — GENERATOR DECALS
The DCA-125USJ generator is equipped with a number of safety decals (Figures 2 and 3). These decals are provided for
operator safety and maintenance information. The illustration below and on the preceding page show the decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
Figure 2. Generator Decals
PAGE 14 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — GENERATOR DECALS
Figure 3. Generator Decals (Cont.)
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DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 15
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DCA-125USJ — INSTALLATION
Figure 4. Typical Generator Grounding Application
PAGE 16 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — INSTALLATION
Outdoor Installation
Generator Grounding
Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to
bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH
generator is on secure level ground so that it cannot slide or ground.
shift around. Also install the generator in a manner so that
Article 250 (Grounding) of the National Electrical Code (NEC)
the exhaust will not be discharged in the direction of nearby
provides guide lines for proper grounding and specifies that
homes.
the cable ground shall be connected to the grounding system
The installation site must be relatively free from moisture of the building as close to the point of cable entry as
and dust. All electrical equipment should be protected from practical.
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
grounding requirements:
NEC articles 250-64(b) and 250-66 set the following
Foreign materials such as dust, sand, lint and abrasive
1. Use one of the following wire types to connect the
materials have a tendency to cause excessive wear to
generator to earth ground.
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
CAUTION - EXHAUST HAZARD
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside.The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
NOTE
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
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DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 17
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DCA-125USJ — GENERAL INFORMATION
DCA-125USJ Series Familiarization
Generator
Open Delta Excitation System
The DCA-125USJ generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
The MQ Power Model DCA-125USJ is a 100 kW generator
(Figure 5) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Pre-heat Lamp
Panel Light/Panel Light Switch
Auto ON/OFF Engine Controller (MPEC)
Fuel Leak Detected Alarm Lamp
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C.This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Generator Control Panel
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
The “Generator Control Panel”is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Engine
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
The DCA-125USJ is powered by a 4 cycle, water cooled,
direct injection, turbocharged JOHN DEERE Model
6068TF275 Diesel Engine.This engine is designed to meet
every performance requirement for the generator.Reference
Table 1 for engine specifications.
3-Pole, 300 amp Main Circuit Breaker
Control Box
The “Control Box”, located behind the Generator Control
Panel, is provided with the following:
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Automatic Voltage Regulator
CurrentTransformer
Electric Governor System
Over-Current Relay
The electric governor system controls the RPMs of the
engine. When the engine demand increases or decreases,
the governor system regulates the frequency variation to
.25%.
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
Voltage Selector Switch
Extension Cables
OutputTerminal Panel
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 5) as a guide
for selecting proper extension cable size.
The “Output Terminal Panel” is provided with the following:
Three 120/240V output receptacles (CS-6369), 50A
Three auxilliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
Battery Charger (Optional)
Water Heater (Optional)
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DCA-125USJ — MAJOR COMPONENTS
Table 3. Generator Major Components
ITEM NO.
DESCRIPTION
Muffler Assembly
1
2
3
4
5
6
7
8
9
Engine Assembly
Enclosure Assembly
Generator Assembly
Output Terminal Assembly
Fuel Tank Assembly
Battery Assembly
Generator Control Panel Assembly
Engine Operating Panel Assembly
Figure 5. Major Components
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DCA-125USJ — GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The definitions below describe the controls and functions of
the DCA-125USJ Generator Control Panel (Figure 6).
1. Main Circuit Breaker – This three-pole, 300A main
breaker is provided to protect the the U,V,andW Output
Terminal Lugs from overload.
The Control Box is equipped with the following major
components:
2. Frequency Meter – Indicates the output frequency in
Over-Current Relay
Voltage Rectifer (AVR)
Starter Relay
CurrentTransformer
Voltage Selector Switch
hertz (Hz). Normally 60 Hz.
3. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
4. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
5. ACVoltmeter – Indicates the output voltage present at
In the event of a short circuit or over current condition, it will
automatically trip the 60 amp main breaker.
the U,V, and W Output Terminal Lugs.
6. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
To restore power to the Output Terminal Panel, press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
7. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
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DCA-125USJ — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
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DCA-125USJ — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of During cranking cycle , The MPEC will attempt to crank the
the DCA-125USJ Engine Operating Panel (Figure 7).
engine for 10 seconds before disengaging. If the engine does
not engage (start) by the third attempt, the engine will be
shutdown by the engine controller’s Over Crank Protection
mode. If the engine engages at a speed (RPM's) that is not
safe, the controller will shutdown the engine by initializing
the Over Speed Protection mode.
1. Panel Light – Normally used in dark areas or at night
time.When activated, panel lights will illuminate.When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup.These conditions
can be observed by monitoring the LED status indicators on
the front of the controller module.
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. When
starting the generator the oil pressure may read a little
higher, but after the engine warms up the oil pressure
should return to the correct pressure range.
A. MPEC Control Switch – This switch controls the
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.
4. WaterTemperature Gauge – During normal operation
this gauge be should read between 180° and 221°F.
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the AUTO position. In this position the
generator will monitor the AC line output from the
building's power source.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
B. Low Oil Pressure – Indicates the engine pressure has
fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a major fault.
8. Pre-Heat Lamp – As the engine cranks, this lamp will
illuminate to indicate automatic preheating of the engine.
When the lamp turns off, the engine has been preheated
and will start automatically.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 239F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
9. Fuel Leak Detected Alarm Lamp – This lamp will
illuminate when a leak in the fuel tank containment
enclosure is detected.
D. Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration. This is considered a major
fault.
10. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical
row of status LED's (inset), that
when lit, indicate that an engine
malfunction (fault) has been
detected. When a fault has
been detected the engine
controller will evaluate the fault
and all major faults will
shutdown the generator.
E. Overspeed Shutdown – Indicates the engine is running
at an unsafe speed. This is considered a major fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
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DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 8) shown below is located
on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
lugs.
The “OutputTerminal Panel ” (Figure 8) is provided with the
following:
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs“O”and “Ground”are
NOTE
considered bonded grounds.
Figure 8. Output Terminal Panel
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DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Each auxilliary receptacle is protected by a 50 amp circuit
breaker.These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
OutputTerminal Lugs.
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker.These breakers are located directly above the GFCI Turn the voltage regulator control knob (Figure 11) on the
receptacles. Remember the load output (current) of both control panel to obtain the desired voltage.Turning the knob
GFCI receptacles is dependent on the load requirements of clockwise will increase the voltage, turning the knob counter-
the UVWO terminals.
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11. Voltage Regulator Control Knob
Removing the Plastic Face Plate (HardWire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 10) provided on the output
terminal panel.These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 12. Plastic Face Plate (Output Terminal Lugs)
Figure 10. 120/240V Twist-Lock
Auxiliary Receptacles
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DCA-125USJ — OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Blower Fan
Loads can be connected to the generator by the OuputTerminal
Lugs or the convienience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
This unit has an intake fan located at the rear of the machine
to draw outside air into the cabinet to cool the engine. The
fan has a 10 amp AC fuse located beneath the Voltage
Selector Switch (Figure 15).
To protect the output terminals from overload, a
3-pole, 300A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Figure 15. Blower Fan Fuse
CAUTION - ELECTRICAL SHOCK HAZARD
The blower fan fuse has current running
through it any time the engine is
operating. This fuse IS NOT connected
to the main circuit breaker of the
generator.Attempting to replace the fuse
with the engine and/or generator
operating could result in electrocution and severe bodily
harm. ALWAYS turn the unit completely off before
attempting to replace or handle the fuse.
Figure 13. Connecting Loads
Over Current Relay
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Figure 14. Over Current Relay
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DCA-125USJ — LOAD APPLICATION
Single Phase Load
Three Phase Load
Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase power
and equipment to insure the wattage, amperage, frequency
,
use the following equation:
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybedeterminedbymultiplying
voltage by amperage by 1.732.
NOTE
If wattage is not given on the
equipment's
name
plate,
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 4 below
when connecting loads.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 5.
Table 4. Power Factor By Load
Type Of Load
Power Factor
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
0.8
Table 5. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Current in
Amperes
At 120
Volts
At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
DANGER - ELECTRICAL SYSTEM HAZARDS
7.5
10
15
20
900
1200
1800
2400
Before connecting this generator to any building’s electrical
system, a licensed electrician must install an isolation
(transfer) switch. Serious damage to the building’s
electrical system may occur without this transfer switch.
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-125USJ — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 16) is located above Table 7 describes the generator’s current output capability
the output terminal panel’s Hard Wire Hook-up Panel. It for both 1Ø-phase and 3Ø phase applications.
has been provided for ease of voltage selection.
Table 7. Generator Ampere Ratings
DCA-125USJ
Single Phase
Three Phase*
kW
kVA
N/A
125
120V
301A x 2
N/A
208V
240V
301A
301A
480V
N/A
72
N/A
100
347A
150A
* Power Factor = 0.8
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the output termi-
nals or the 3 twist lock auxilliary receptacles.
Tables 8 and 9 show what amount of current is available at
the GFCI receptacles when the output terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the recep-
tacles.
Figure 16. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
Table 8. 1
Ø
GFCI Receptacle Load Capability
KW in Use
Available Load
Twist-Lock (CS6369)
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
1Ø 240/120V
72
0
CAUTION -VOLTAGE SELECTOR SWITCH
70.8
69.6
68.4
67.2
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
NEVER change the position of the voltage selector
switch while the engine is runnng. ALWAYS place circuit
breaker in the open position before selecting voltage.
Table 9. 3 GFCI Receptacle Load Capability
Ø
Generator OutputVoltages
KVA in Use
Available Load
(UVWO Terminals)
Current (Amps)
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 15). To obtain some of
the voltages as listed in Table 6 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
3Ø 240/480V
GFCI Duplex NEMA
5-20R 120V
125
121
117
113
108
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 6. Voltages Available
Three Phase
208V
220V
240V
416V
440V
254V
480V
277V
(Switchable)
Single Phase
(Switchable)
120V
127V
139V
240V
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DCA-125USJ — GAUGE READING
How to Read the OutputTerminal Gauges.
Reading Amperage
The gauges and selector switches on the control panel To determine the amperage at a terminal lug, set the
DO NOT effect the generator output. They are provided to AC Ammeter Change-Over Switch to the appropriate
help observe how much power is being supplied at the setting (Figure 20) to activate the AC Ammeter Gauge
Output terminals lugs.
(Figure 21) and read the available amperage at the terminal
lug.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 17) to the position which produces For example, to measure the amperage at the U
the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the volt-
terminal lug, set the AC Ammeter Change-Over Switch to
U and read the AC Ammeter Gauge.
age selector switch.)
Figure 17. Voltage
Selector Switch 240/
139VThree Phase
Position
Figure 21. AC Ammeter
(Amp reading on U lug)
Figure 20. AC Ammeter
Change-Over Switch
For 3Ø 208V/1Ø,120V, place
NOTE
the Voltage Selector Switch
in the 3 Phase 340/139
position.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
Reading Voltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 18) to activate the AC Voltmeter Gauge
(Figure 19) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the ACVoltmeter Gauge.
Figure 18. AC Voltmeter Figure 19. AC Voltmeter Gauge
Change-Over Switch
(Volt reading on W-U Lug)
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DCA-125USJ — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V OutputTerminal Lug Voltages
Various output voltages can be obtained using the Output
Terminal Lugs.. The voltages at the terminals are depen-
dent on the position of the Voltage Selector Switch and the
adjustment of the Voltage Regulator Control Knob.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 25.
Use this position for
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3Ø 240/139 OutputTerminal Lug Voltages
Figure 25. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 26.
Figure 22. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 23.
Figure 26. Output Terminal Lugs
3Ø-208V/120V Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 23. Output Terminal Lugs
240/139VThree Phase Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V output
the voltage selector switch
must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.
NOTE
Figure 24. Voltage Regulator Knob (139V/240V)
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DCA-125USJ — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal LugVoltages
1Ø 240V/120V OutputTerminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 29.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 29. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 28.
shown in Figure 30.
Figure 28. UVWO Terminal Lugs
480/277V Three Phase Connections
Figure 30. UVWO Terminal Lugs
1Ø-240V/120V Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
1
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DCA-125USJ — PRE-SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 110 amp,
main circuit breaker is provided to protect the U,V, and W
OutputTerminals from overload.In addition two single-pole,
20 amp GFCI circuit breakers are provided to protect the
GFCI receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 31) on the dipstick. See Table 10 for proper
selection of engine oil.
Refilling the Fuel System
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
Figure 31. Engine Oil Dipstick
The generator unit has an internal fuel tank located at the
bottom of the cabinet (Figure 32). ALWAYS fill the fuel tank
with clean and fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the John Deere Engine Owner's Manual. Oil should be
warm before draining.
Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
Table 10. Recommended Motor Oil
OIL: SAE
F
C
122
104
86
50
40
30
20
10
0
68
50
32
-14
-4
-10
-20
-30
-40
Figure 32. Internal Fuel Tank System
-22
-40
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DCA-125USJ — PRE-SETUP
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
2. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel cap
and fill tank (Figure 34).
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
CAUTION - REFUELINGTHE GENERATOR
ALWAYS place trailer on firm level ground before refueling
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
Figure 34. Fueling the Generator
3. NEVER overfill fuel tank – It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait for
fuel to rise in filler neck (Figure 35).
Figure 33. Only Fill on Level Ground
ONLY! use #2 diesel fuel when
refueling.
NOTE
Figure 35. Full Fuel Tank
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 36).
Figure 36. Fuel Expansion
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DCA-125USJ — PRE-SETUP
Coolant (John Deere Antifreeze/Summer Coolant/Water)
John Deere recommends John Deere Antifreeze/Summer
Coolant for use in thier engines, which can be purchased in
concentrate (and mixed with 50% demineralized water) or
pre-diluted. See the John Deere Engine Owner's Manual
for further details.
NOTE
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
negative battery terminal disconnected.
WARNING - BURN HAZARDS
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled.The
possibility of hot! coolant exists which
can cause severe burns.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.
Ifaddingcoolant/antifreeze mix to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. The
possibility of hot! coolant exists which can cause severe
burns.
Fan BeltTension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Deere Engine Owner's Manual.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 11 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 37) when depressed with the thumb as shown
below.
Table 11. Coolant Capacity
Engine and Radiator
Reserve Tank
4.4 Gal. (16.8 liters)
2 Quarts (1.9 liters)
Figure 37. Fan BeltTension
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 12) has been added.
CAUTION - ROTATING PARTS
Table 12. Anti-Freeze
Operating Temperatures
NEVER place hands near
the belts or fan while the
generator set is running.
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
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DCA-125USJ — PRE-SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or
malfunctions. Always keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
If the battery cable is connected
incorrectly, electrical damage to
the generator will occur. Pay close
NOTE
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
attention to the polarity of the
battery when connecting the
battery.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
CAUTION - BATTERY SERVICING SAFETY
Battery Cable Installation
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ALWAYS be sure the battery cables (Figure 38) are properly
connected to the battery terminals as shown below. The
RED cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
Alternator
The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
in short circuit instantaneously resulting the alternator failure.
CAUTION - BATTERY SERVICING SAFETY
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
Figure 38. Battery Connections
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DCA-125USJ — GENERATOR START-UP PROCEDURE (MANUAL)
Before Starting
5. Place the voltage selector switch
in the desired voltage position
(Figure 41).
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
Figure 41. Voltage Selector
Switch
WARNING - STARTINGTHE GENERATOR
Starting (Manual)
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
8. Place the MPEC Control Switch in the MANUAL
position to start the engine (Figure 42).
1. Place the main, G.F.C.I. and aux. circuit breakers (Figure 39)
in the OFF position prior to starting the engine.
Figure 42. MPEC Control Switch
(Manual Position)
In cold weather conditions, placing the MPEC Control
Switch in the MANUAL position will preheat and start
the engine AUTOMATICALLY. The Preheat Lamp
(Figure 43) will turn off when the engine has started.
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
7. Once the engine starts, let the engine run for 1-2 minutes.
Listen for any abnormal noises.
2. Connect the load to the receptacles or the Output
Terminal Lugs as shown in Figure 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
3. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
Figure 43. Pre-Heat Lamp
4. Close all engine enclosure doors (Figure 40).
8. Verify that the Engine Running
status LED on the MPEC unit
(Figure 44) is ON (lit) after the
engine has been started.
Figure 44. Engine Running
LED (ON)
Figure 40. Engine Enclosure Doors
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DCA-125USJ — GENERATOR START-UP PROCEDURE (MANUAL)
9. The generator's frequency meter (Figure 45) should be 13. The coolant temperature gauge (Figure 50) will indicate
displaying the 60 cycle output frequency in HERTZ.
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
Figure 45. Frequency Meter (Hz)
10. The generator's AC-voltmeter (Figure 46) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 47) to increase or decrease the
desired voltage.
Figure 50. Coolant Temperature Gauge
14. The tachometer gauge (Figure 51) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 46. Voltmeter
Figure 51. Engine Tachometer Gauge
15. Place the main, GFCI, and aux. circuit breakers in the
Figure 47. Voltage Adjust
Control Knob
ON position (Figure 52).
11. The ammeter (Figure 48) will
indicate zero amps with no load
applied. When a load is applied,
the ammeter will indicate the
amount of current that the load is
drawing from the generator.
Figure 48. Ammeter (No Load)
12. The engine oil pressure gauge
(Figure 49) will indicate the oil
pressure (kg/ cm2) of the engine.
Under normal operating conditions
the oil pressure is approximately
35~65 PSI.
Figure 52. Main, Aux. and GFCI
Circuit Breakers (ON)
Figure 49. Oil Pressure Gauge
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DCA-125USJ — GENERATOR START-UP PROCEDURE (AUTO MODE)
16. Observe the generator's ammeter (Figure 53) and verify
WARNING - AUTO MODE MAINTENANCE
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if a load is in use.
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
CAUTION - ENGINE SPEED SWITCH
The Engine Speed Switch must be set to the “High”
position when running in the Auto-Start mode.Failing to
set the switch in the proper position can result in damage
to your generator when it turns on.
Figure 53. Ammeter (Load)
17. The generator will run until manually stopped or an
abnormal condition occurs.
When the MPEC Control Switch
is placed in the AUTO position,
the engine glow plugs will be
warmed and the engine will start
automatically.
Starting (Auto Mode)
NOTE
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to the
building’s electrical system may occur
without this transfer switch.
When starting generator in AUTO mode use the "Manual
Start-up" procedure except where noted (see below).
1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.
CAUTION - BACKUP GENERATOR USE
2. Place the MPEC Control Switch (Figure 54) in the AUTO
position
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
Figure 54. MPEC Control Switch (AUTO)
When the generator is set in the
AUTO mode, the generator will
3. Continue operating the generator as outlined in the
automically start in the event of
comercial power falling below a
Manual Start-up procedure (start at step 9).
NOTE
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
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DCA-125USJ — GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
WARNING - SHUTTING DOWNTHE GENERATOR
1. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 38) circuit
breakers to OFF position.
NEVER stop the engine suddenly except in an emergency.
Normal Shutdown Procedure
2. Place the MPEC Control Switch switch (Figure 55) to
To shutdown the generator use the following procedure:
the OFF/RESET position.
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 38 to the OFF position.
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 55) to the
OFF/RESET position.
Figure 55. MPEC Control Switch (Off/Reset)
5. Verify that the all status LED’s on the MPEC display
are OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occured during operation.
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DCA-125USJ — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 13. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
1
Replace Engine Oil and Filter *
X
X
Clean Air Filter
ENGINE
Check Fuel Filter/Water Seperator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
X
X
X
X
Clean Radiator and Check Coolant Protection Level*2
3
Replace Air Filter Element *
X
4
Check all Hoses and Clamps *
X
X
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
Check Rotor Rear Support Bearing
X
GENERATOR
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Add "Supplemental Coolant Addatives (SCA'S)" to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the bloby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.
General Inspection
Service Daily
Prior to each use, the generator should be cleaned and inspected
for deficiencies. Check for loose, missing or damaged nuts, bolts
or other fasteners. Also check for fuel, oil, and coolant leaks.
If the engine is operating in very dusty or dry grass conditions, a
clogged air cleaner will result.This can lead to a loss of power,
excessive carbon buildup in the combustion chamber and high
fuel consumption. Change air cleaner more frequently if these
conditions exists.
Engine Side (Refer to the Engine Instruction Manual)
Air Cleaner
Fuel Addition
Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.
Add diesel fuel (the grade may vary according to season and
locations).
RemovingWater from the FuelTank
Air Cleaner with Dust Indicator
After prolonged use, water and other impurities accumulate in
the bottom of the tank. Occasionally inspect the fuel tank for
water contamination and drain the contents if required.
This indicator is attached to the air cleaner.When the air cleaner
element is clogged, air intake restriction becomes greater and
the dust indicator signal shows RED meaning the element needs
changing or service. After changing the air element, press the
dust indicator button to reset the indicator.
During cold weather, the more empty volume inside the tank,
the easier it is for water to condense.This can be reduced by
keeping the tank full with diesel fuel.
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DCA-125USJ — MAINTENANCE
Air Removal
Flushing Out Radiator and Replacing Coolant
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure. See the John Deere
Engine Manual for details.
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant.Open the
radiator cap while draining. Remove the overflow tank
and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level.The oil level
must be between the two notches on the dipstick as shown
in Figure 33.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed.DO NOT
clean radiator core with any objects, such as a
screwdriver.
Tighten both cocks and replace the overflow tank.
Replacing Oil Filter
Replace with coolant as recommended by the engine
manufaturer.
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
Close radiator cap tightly.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
WARNING - BURN HAZARDS
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Generator Storage
For longe term storage of the generator the following is
recommended:
Vent any air.
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
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DCA-125USJ — MAINTENANCE
Jacket Water Heater and Internal Battery Charger
120VAC Input Receptacles (OPTIONAL)
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
This generator can be optionally equipped with two 120VAC,
20 amp input receptacles located on the output terminal
panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger.
NOTE
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 56). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 5).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.
Figure 56. DCA-45SIU2 Battery Charger &
Jacket Water Heater Power Connections
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DCA-125USJ —TRAILER BRAKES MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 57) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 60 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
star wheel of the adjuster assembly to expand the brake
shoes.
Figure 57. Hydraulic Brake Components
Actuator
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the surge or push of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
Periodically check and test the surge “actuator” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 14. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
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DCA-125USJ —TRAILER MAINTENANCE
Suspension
Tires/Wheels/Lug Nuts
The leaf suspension springs and associated components
(Figure 58) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 16.
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION - EYESIGHT HAZARD
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRINGTRAILERWHEELS
DO NOT attempt to repair or modify a wheel. DO NOT
install in inner tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Figure 58. Major Suspension Components
Tire Wear/Inflation
Table 16. Suspension Torque Requirements
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot!. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Item
Torque (Ft.-Lbs.)
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
Table 15 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
SHACKLE BOLT
TABLE 15. TIRE WEARTROUBLESHOOTING
SPRING EYE BOLT
SOLUTION
CAUSE
WEAR PATTERN
Adjust pressure to
particular load per tire
manufacturer.
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Over Inflation.
Center Wear
Adjust pressure to
particular load per tire
manufacturer.
Make sure load does
not exceed axle rating.
Align wheels.
Under Inflation.
Edge Wear
Side Wear
Loss of camber
or overloading.
Toe Wear
Cupping
Incorrect toe-in.
Out-of-balance.
Align wheels.
Check bearing adjustment
and balance tires.
Wheel lockup &
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Flat Spots
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DCA-125USJ —TRAILER MAINTENANCE
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 59). DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 17.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 17. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 59. Wheel Lug Nuts
Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
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DCA-125USJ —TRAILERWIRING DIAGRAM
Figure 60. Trailer/Towing Vehicle Wiring Diagram
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DCA-125USJ — GENERATORWIRING DIAGRAM
Figure 61. Generator Wiring Diagram
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DCA-125USJ — ENGINEWIRING DIAGRAM
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DCA-125USJ —TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 18 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.
TABLE 18. GENERATOR TROUBLESHOOTING
SYMPTOM
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Defective Exciter Field?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Check for 17.3 ohms across J & K on CN1
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
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DCA-125USJ —TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor
Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
TABLE 19. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in Controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light is
on.
Inspect/repair wire.
Low coolant level?
Fill coolant level.
Low coolant level light is
on. (Optionally Installed)
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Clean/repair radiator grill.
Close doors.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through radiator?
Doors open?
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
High coolant temperture
light is on.
Generator being overloaded?
Thermostat failure?
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
Controller needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
Engine Controller needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust RPM.
Adjust governor actuator.
Adjust governor controller.
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU light(s) or
on.
PAGE 50 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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NOTE PAGE
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 51
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DCA-125USJ — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
1
2%
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
WASHER, 3/8 IN....1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items.Examples include battery cables, shims,
and certain washers and nuts.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
“Not Sold Separately”— Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
PAGE 52 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — SUGGESTED SPARE PARTS
DCA-125USJW/JOHN DEERE
4045TF275 DIESEL ENGINE
1TO 3 UNITS
Qty.
P/N
Description
5 .............. 0602041292 ........................FILTER, OIL
5 .............. 0602042594 ........................FILTER, FUEL, PRIMARY
5 .............. 0602042595 ........................FILTER, FUEL, FINAL
3 .............. 0602046377 ........................ELEMENT, AIR
1 .............. 0602011493 ........................BELT, FAN
1 .............. 0605505070 ........................CAP. FUEL TANK
1 .............. 0602122272 ........................UNIT, OIL PRESSURE
1 .............. 0602123261 ........................UNIT, WATERTEMPERATURE
2 .............. 0601802149 ........................FUSE, 10A
1 .............. 0602123282 ........................SENDER, WATER SWITCH (ENGINE SIDE)
1 .............. 0602122281 ........................SENDER, OIL SWITCH (ENGINE SIDE)
1 .............. 060122272 ..........................UNIT, OIL PRESSURE
1 .............. 0602123261 ........................UNIT, WATERTEMPERATURE
Part number on this Suggested Spare Parts
list may supercede/replace the P/N shown
in the text pages of this book.
NOTE
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 53
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DCA-125USJ — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 54 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
ROTOR ASSY.
FIELD ASSY.
FAN
QTY.
REMARKS
C0110000002
1
1
1
8
1-1
*
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
8131070013
8131611014
8131015003
0012112035
0042612000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906312
C0130000503
0845041804
8131315202
8101350013
0012110060
0042610000
0041210000
0010112035
0041212000
0041212000
8131310104
8131312204
8131331003
0017106012
8101333003
0010106030
0040006000
0041206000
M3163400003
0343204150
0043604000
0070506306
0012810030
0012810030
8131332014
0600815000
0605000063
0030016000
0040016000
*
*
*
*
*
*
*
*
COUPLING DISK
BALANCING PLATE ............................................1 ............. PURCHASE SET OF 1-14
HEX HEAD BOLT
SPRINGWASHER
SET PLATE, RECTIFIER ....................................1 ............. PURCHASE SET OF 1-14
RECTIFIER .........................................................2 ............. PT3610
SURGE ABSORBER...........................................1 ............. ERZ-M14JK621A
INSULATORWASHER
INSULATORWASHER
HEX, HEAD BOLT
SPRINGWASHER
BALANCING WEIGHT KIT
10
10
1-10
1-11
1-12
1-13
1-14
1-15
2
1
1
4
4
1
*
*
*
*
*
*
BEARING ............................................................1 ............. 6312DDUC3
STATOR ASSY.
GROMMET
END BRACKET
1
2
1
1
4
4
4
6
6
6
1
1
1
10
1
2
2
2
1
8
8
1
12
12
1
1
2
3
4
5
6
7
8
9
FIELD ASSY. EXCITER
HEX, HEAD BOLT
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
SPRINGWASHER
PLAIN WASHER
COVER, BEARING
GASKET, BEARING
COVER, END BRACKET
HEX, HEAD BOLT
COVER, END BRACKET
HEX, HEAD BOLT
SPRINGWASHER
PLAIN WASHER
COUPLING RING
HEX, HEAD BOLT
SPRINGWASHER
BEARING, 6306ZZ
HEX, HEAD BOLT
HEX, HEAD BOLT
COVER, FAN
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A
NUT
RUBBER SUSPENSION, KA120SS
HEX, NUT
SPRINGWASHER
2
2
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 55
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DCA-125USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 56 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
CONTROL BOX
EDGING
QTY.
1
2
REMARKS
M3213000702
0330000180
0601808823
0021006080
0601823863
0027104016
0601820671
0027105016
0601806118
0027106016
0601820845
0601820846
0027104016
0207004000
M3213500013
0016906016
M3270100104
047230402
CIRCUIT BREAKER, 300A ............................... 1 ........... LAF3630010393P
MACHINE SCREW
RELAY UNIT ..................................................... 2 ........... MSA9013A
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR................ 1 ........... NTA-5A-2DB
MACHINE SCREW
CURRENTTRANSFORMER ............................. 3 ........... 814-943 200/5A
MACHINE SCREW
OVER CURRENT RELAY .................................. 1 ........... LR2D1308
OVER CURRENT RELAY .................................. 1 ........... LA7D1064
MACHINE SCREW
HEX, NUT
CONTROL BOX COVER
HEX, HEAD BOLT
SELECTOR SWITCH ........................................ 1 ........... XUSS01574
KNOB, SELECTOR SWITCH
SPACER
SWITCH BRACKET
EDGING
MACHINE SCREW
HEX, HEAD BOLT
SWITCH COVER
HEX, HEAD BOLT
HEX, HEAD BOLT
TOOTHEDWASHER
CONTROL PANEL
FREQUENCY METER ...................................... 1 ........... FCF-6 45~65Hz 240V
AC AMMETER .................................................. 1 ........... ACF-6 0~200A/400A:5A
CHANGE-OVER SWITCH, AMMETER ............. 1 ........... SL-2AS
4
4
4
9
10
11
12
13
13A
14
15
16
16A
17
18
19
20
21
22
23
24
24A
25
26
27
28
29
30
6
2
2
1
4
1
8
1
2
4
6
1
4
10
1
M3276600004
M3213600503
03300003330
0027104010
0016906016
M3213600604
0016906016
0016906016
0040506000
M3223000503
0601807641
0601808988
0601801040
0601806859
0601801041
1
AC VOLTMETER ............................................... 1 ........... SCF-6 0~600V
CHANGE-OVER SWITCH, VOLTMETER .......... 1 ........... SL-2VS
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 57
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DCA-125USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 58 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
31
32
33
34
35
35A
36
36A
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
52A
52B
53
54
57
57A
58
58A
60
61
62
63
64
PART NO.
PART NAME
RHEOSTAT (VOLTAGE REGULATOR) ............... 1 ........... RA20A2SE102BJ 2W 1k OHM
KNOB
CONTROLLER .................................................. 1 ........... REPLACES 0602202593
SWITCH ............................................................ 1 ........... 7562K4
QTY.
REMARKS
0601840073
0601840121
ECU9988NJD
0601831340
0027104040
0207004000
0602103092
0601810245
0602120096
0602122093
0602123092
0602121080
0602125090
0601810141
0601831330
M1223100004
M3223100004
0027105010
0027105010
M9220100004
0080200007
0602202592
0027106018
LY2DDC12V
PTF08A
1
MACHINE SCREW
HEX, NUT
2
2
PREHEAT LAMP ............................................... 1 ........... PL-05
BULB
1
TACHOMETER .................................................. 1 ........... 111812
OIL PRESSURE GAUGE .................................. 1 ........... 100174
WATERTEMPERATURE GAUGE ..................... 1 ........... 100182
CHARGING AMMETER .................................... 1 ........... 100158
FUEL GAUGE.................................................... 1 ........... 100176
PANEL LIGHT.................................................... 1 ........... 8826800370
SWITCH, PANEL LIGHT ................................... 1 ........... 90-0001
STOPPER
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
1
1
4
4
2
2
STARTER RELAY .............................................. 1 ........... AT141011
MACHINE SCREW
RELAY
BASE
CLIP
MACHINE SCREW
2
1
1
2
2
PYCA1
0027104020
0601823240
0602122272
M9200100004
0602123261
0602021109
M3246701904
M3357201102
M3357200304
0601802149
0601823240
0602103092
0601810245
RECTIFIER ....................................................... 1 ........... DE4503
UNIT, OIL PRESSURE ...................................... 1 ........... 108497
ADAPTOR
1
UNIT, WATERTEMPERATURE ......................... 1 ........... 02025-00
PACKING
WIRE HARNESS, GENERATOR
WIRE HARNESS, ENGINE
1
1
1
WIRE HARNESS, FUEL LEAK ......................... 1 ........... 8400041~
FUSE................................................................. 2 ........... F-106510A
RECTIFIER ....................................................... 1 ........... DE4503
ALARM LAMP, PL095........................................ 1 ........... 8400041~
BULB ................................................................. 1 ........... 8400041~
65
65A
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 59
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DCA-125USJ — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 60 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO.
1
1-1
1-2
1-3
1-4
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
M3923200054
0602041292
0602042594
0602042595
0602011493
0602060003
0602061000
0012110095
0042510000
M2303200303
0010312030
0040012000
0605000060
0030012000
0040012000
C0923200124
0602011062
M9200100904
0150000016
M3131300103
0016910025
0016910025
M3310500813
M3310500903
0605515148
0605515147
0601822794
0017110035
0602046258
0602046377
0602040650
0602040596
0016908020
0207008000
M3373100003
0605515146
ENGINE & RADIATOR SET .................................1........ JOHN DEERE 6068TF275
CARTRIDGE, OIL FILTER ....................................1........ RE504836
CARTRIDGE, PRIMARY, FUEL FILTER ...............1........ RE517181
CARTRIDGE, FINAL, FUEL FILTER ....................1........ RE509031
FAN BELT .............................................................1........ 2402
BLOWER FAN ......................................................1........ AT39247
FAN SPACER .......................................................1........ R81911
HEX, HEAD BOLT
SPRINGWASHER
ENGINE FOOT
HEX, HEAD BOLT
SPRINGWASHER
RUBBER SUSPENSION
HEX, NUT
SPRINGWASHER
RADIATOR
CAP, RADIATOR
PLUG
4
4
2
6
6
2
2
2
1
1
1
1
1
6
4
1
1
3
1
2
8
7
8
9
10
11
12
12A
13
14
15
16
17
18
19
20
21
22
23
24
24A
25
26
27
28
29
30
O RING
FAN BRACKET
HEX, HEAD BOLT
HEX, HEAD BOLT
RADIATOR HOSE
RADIATOR HOSE
HOSE BAND
HOSE BAND
FAN MOTOR
HEX, HEAD BOLT
AIR CLEANER .....................................................1........ FRG100297
ELEMENT, AIR CLEANER ...................................1........ P778214
INDICATOR, AIR CLEANER .................................1........ RBXO0-2252
BAND, AIR CLEANER
HEX, HEAD BOLT
HEX, NUT
2
4
4
1
1
HOSE, AIR CLEANER
HOSE BAND
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 61
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DCA-125USJ — ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 62 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — ENGINE AND RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
52
53
54
55
56
57
58
PART NO.
PART NAME
HOSE BAND
ADAPTER
90 DEGREE ELBOW
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HEX, HEAD BOLT
HOSE
HOSE
HOSE
HOSE BAND
BLOWBY HOSE
HOSE BAND
RELAY BRACKET
RELAY ............................................................... 1 ........... AT141011
MACHINE SCREW
HEX, NUT
HEX, HEAD BOLT
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
REMARKS
0605515197
0602022563
0602022561
0603306590
0603300285
0605511395
0603306395
0602021070
0269200450
M9300000203
0602010900
M3316100303
0016908020
0199102200
0193600700
0193601000
0605515106
M3326000204
0605515149
M3260600104
0602202592
0027106016
0030006000
0017112025
0040512000
0602122281
0602123282
3
1
1
1
2
2
1
1
1
1
TOOTHEDWASHER
SENDER, OIL PRESSURE
SENDER, WATER PRESSURE
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 63
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DCA-125USJ — OUTPUTTERMINAL ASSY.
OUTPU
PAGE 64 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
5
REMARKS
M3230700003
M9220100304
M9220100404
0039316000
0040016000
0041416000
0016908035
M3236100503
M3236100404
0605010040
0027103010
0030003000
0041203000
0027103010
0030003000
0016906020
0016906016
M3236400004
M3236300004
0016906020
0601808803
0601808804
M1260700304
022100150
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX, NUT
10
15
20
5
1
1
2
4
4
4
4
4
2
4
1
1
6
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
HEX, NUT
PLAIN WASHER
MACHINE SCREW
HEX, NUT
HEX, HEAD BOLT
HEX, HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX, HEAD BOLT
CIRCUIT BREAKER, 1-POLE 20A.................... 2 ........... QOU 120B
CIRCUIT BREAKER, 2-POLE 50A.................... 3 ........... QOU 250B
BREAKER FITTING COVER
CUSHION RUBBER
HEX, HEAD BOLT
RECEPTACLE ................................................... 2 ........... GF530EM 125V 20A X 2
RECEPTACLE ................................................... 3 ........... CS6369 250V 50A
MACHINE SCREW
HEX, NUT
TERMINAL COVER
HEX, HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX, NUT
9
10
11
11A
11B
12
12A
13
14
15
16
17
18
19
20
20A
21
22
23
24
24A
25
26
27
28
29
30
31
32
33
1
1
2
0016906020
0601812598
0601812538
0027104016
0207004000
M3236100213
0010112045
0041212000
M9310200004
0030012000
0603306775
0027104016
0601815194
0027104016
10
10
1
2
2
2
2
2
4
BLIND PLUG
MACHINE SCREW
TERMINAL
1
2
MACHINE SCREW
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 65
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DCA-125USJ — BATTERY ASSY.
BATTERY ASSY.
PAGE 66 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
PART NO.
PART NAME
QTY.
REMARKS
0602220196
M9310500404
M9103000504
0602220921
M3346900904
M3346901004
BATTERY ....................................................... 1 ............. 4D-2
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
BATTERY CABLE
BATTERY CABLE
1
1
2
1
1
7
8
8A
9
9A
10
CABLE ........................................................... 1 ............. MAKE LOCALLY
0030012000
0040012000
0017112025
0040512000
0040520000
HEX, NUT
1
1
1
1
1
SPRINGWASHER
HEX, HEAD BOLT
TOOTHEDWASHER
TOOTHEDWASHER
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 67
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DCA-125USJ — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 68 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
7
8
9
9
10
PART NO.
PART NAME
MUFFLER
HEX, HEAD BOLT
EXHAUST PIPE
GASKET
HEX, HEAD BOLT
GASKET
HEX, HEAD BOLT
HEX, HEAD BOLT ............................................. 4 ........... S/N 8500015~
EXHAUST PIPE
HEX, HEAD BOLT
HEX, HEAD BOLT ............................................. 4 ........... S/N 8500015~
CLAMP
QTY.
REMARKS
M3330100402
0017112030
M3333000903
M3333200304
0017110040
M3333200204
0017108040
0017110035
M3333000803
0016908055
0017110050
0602325066
1
4
1
1
4
1
4
1
4
1
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 69
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DCA-125USJ — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 70 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
1A
1B
1C
2
2A
3
4
5
6
7
8
8A
8B
8C
9
10
11
12
13
14
15
16
17
18
PART NO.
PART NAME
QTY.
1
1
1
1
1
1
2
4
8
8
8
4
8
4
12
1
2
REMARKS
M3363001402
0605505070
0605501074
0605516090
M3363001504
0605505070
0191700260
0605515149
M3363200404
M9310500104
0016908020
0016908055
0030008000
0207308000
0041208000
0191302500
0605515109
0191301200
0191301200
0605515109
0602042601
0222101000
0605512190
0605511190
0605512191
FUELTANK
FUEL TANK CAP
FUEL SENDER UNIT
GASKET
FUELTANK
FUEL TANK CAP
CONNECT HOSE
HOSE BAND
TANK BAND
SUPPORTER SHEET
HEX, HEAD BOLT
HEX, HEAD BOLT
HEX, NUT
HEX, NUT
PLAIN WASHER
VENT HOSE
HOSE BAND
SUCTION HOSE
RETURN HOSE
HOSE BAND
RETURN PIPE .................................................. 1 ........... RE67050
TANK SHEET
HOSE JOINT
PICKUP ELBOW
HOSE JOINT 1/4-18 NPT
1
1
4
6
1
1
1
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 71
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DCA-125USJ — ENCLOSURE #1 ASSY.
PART
ANEL TO
ELLOW
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 72 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO.
1
2
3
4
5
5
5A
5A
5A
6
PART NO.
PART NAME
BASE
ENVIRONMENTALTANK
HEX, HEAD BOLT
PLUG
FRONT FRAME................................................. 1 ........... S/N 8500001TO 8500040
FRONT FRAME................................................. 1 ........... S/N 8500041~
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001TO 8500035
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036TO 8400040
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~
FRONT FRAME................................................. 1 ........... S/N 8500001TO 8500040
FRONT FRAME................................................. 1 ........... S/N 8500041~
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001TO 8500035
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036TO 8500040
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~
GROMMET........................................................ 1 ........... S/N 8500036TO 8500040
GROMMET........................................................ 1 ...........
QTY.
1
1
12
1
REMARKS
M3413001812
M3363300303
0016910030
0603306797
M3423001202
M3423001602
M3493107813
M3493107823
M3493111303
M3423001302
M3423001702
M3493107813
M3493107823
M3493111303
0601851739
0601850100
0016908020
0016910025
M3131400203
M3131400103
M3131400004
0016908020
0016906020
M3423500104
0016906016
M3423200704
0016906020
M3423200804
0016906016
M3310300104
M3310300004
0016906020
M3423201003
M3423201203
M3423201703
M3493107904
0016908020
0019208020
M3433000803
M3433000813
6
6A
6A
6A
7
8
9
HEX, HEAD BOLT
HEX, HEAD BOLT
26
6
10
11
11A
11B
12
12
13
14
15
16
17
18
19
20
21
22
22
22
22A
23
23
24
24
HOSE COVER ................................................... 1 ........... S/N 8500001TO 8500040
HOSE COVER ................................................... 1 ........... S/N 8500041~
HOSE COVER ................................................... 1 ........... S/N 8500041~
HEX, HEAD BOLT ............................................. 4 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ........................................... 13 ........... S/N 8500041~
BRACKET
1
6
2
14
1
6
1
1
14
HEX, HEAD BOLT
DUCT COVER
HEX, HEAD BOLT
DUCT COVER
HEX, HEAD BOLT
FAN SHROUD
FAN SHROUD
HEX, HEAD BOLT
COVER, FRONT FRAME .................................. 1 ........... S/N 8500001TO 8500035
COVER, FRONT FRAME .................................. 1 ........... S/N 8500036TO 8500322
COVER, FRONT FRAME .................................. 1 ........... S/N 8500323 ~
ACOUSTIC SHEET
1
HEX, HEAD BOLT ........................................... 26 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ........................................... 26 ........... S/N 8500041~
CENTER FRAME .............................................. 1 ........... S/N 8500001TO 8500035
CENTER FRAME .............................................. 1 ........... S/N 8500036~
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 73
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DCA-125USJ — ENCLOSURE #1 ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 74 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO.
24A
24A
25
25A
25B
25C
26
26A
26B
26C
27
27A
28
28A
29
30
31
31A
32
33
34
35
35A
36
36
37
37
38
PART NO.
PART NAME
QTY.
REMARKS
M3493200614
M3493201204
0010114040
0030014000
0040014000
0041214000
0010120050
0030020000
0040020000
0041220000
M3463100802
M3493503914
M3463200502
M3493504003
M3463200704
0016906016
M3463200803
M3493504104
0016908020
M3463400003
0016908020
M3423200604
M3493108004
0016908020
0019208020
0016910025
0019210025
M3310600004
0016908020
0016908020
M3483100004
0016908020
0016908020
0040508000
0016906016
0605503062
M1414800104
0017108020
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001TO 8500040
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500041~
HEX, HEAD BOLT
HEX, NUT
SPRINGWASHER
PLAIN WASHER
HEX, HEAD BOLT
HEX, NUT
SPRINGWASHER
PLAIN WASHER
ROOF PANEL
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
BACK PLATE
HEX, HEAD BOLT
DUCT
ACOUSTIC SHEET
HEX, HEAD BOLT
DUCT COVER
HEX, HEAD BOLT
OVER COVER, FRONT FRAME
ACOUSTIC SHEET
HEX, HEAD BOLT ........................................... 49 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ........................................... 49 ........... S/N 8500041~
HEX, HEAD BOLT ............................................. 8 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ............................................. 8 ........... S/N 8500041~
COVER, RADIATOR CAP
HEX, HEAD BOLT
HEX, HEAD BOLT
COVER, EXHAUST PIPE
HEX, HEAD BOLT ............................................. 2 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ............................................. 1 ........... S/N 8500041~
TOOTHEDWASHER
4
4
4
8
4
4
4
8
1
1
1
1
1
6
1
1
8
1
6
1
1
1
4
6
1
39
40
41
42
43
43A
44
45
46
1
HEX, HEAD BOLT ............................................. 2 ........... S/N 8500001TO 8500035
FUEL LEAK DETECTION SWITCH .................. 1 ........... S/N 840003~
BRACKET ......................................................... 1 ........... S/N 840003~
HEX HEAD BOLT .............................................. 2 ........... S/N 840003~
47
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 75
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DCA-125USJ — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 76 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO.
1
1
1A
2
2
2A
3
4
5
5A
6
PART NO.
PART NAME
QTY.
REMARKS
M3443000802
M3443000812
M3493303203
M3443000904
M3443000914
M3493303304
0016908020
0016910025
M3443301003
M3493303404
0016908020
M3443200503
M3443600304
0207306000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
M3453200802
M3453200812
M3493417004
M3493417014
0016908065
0016910025
M3453002503
M3493416804
M3453002603
M3493416904
M3453002703
M3493417204
M3453002803
M3493417104
M9113000002
C9312500004
0021806016
0030006000
M9110100804
M9110100904
M9116100004
0016908020
0019208020
0601850097
0027208025
M9310000004
REAR FRAME ................................................... 1 ........... S/N 8500001TO 8500035
REAR FRAME ................................................... 1 ........... S/N 8500036~
ACOUSTIC SHEET
1
DUCT ................................................................. 2 ........... S/N 8500001TO 8500035
DUCT ................................................................. 2 ........... S/N 8500036~
ACOUSTIC SHEET
HEX, HEAD BOLT
HEX, HEAD BOLT
COVER, REAR FRAME
ACOUSTIC SHEET
HEX, HEAD BOLT
DOOR, REAR FRAME
WINDOW PLATE
HEX, NUT
PLAIN WASHER
DOOR HANDLE ASSY.
MACHINE SCREW
HEX, NUT
2
26
4
1
1
13
1
1
8
8
1
4
4
2
2
3
7
8
9
9A
10
11
11A
12
13
14
15
15
15A
15A
16
17
18
18A
19
19A
20
20A
21
21A
22
22A
23
23A
24
25
26
27
27
28
29
30
HINGE
WASHER
HEX, HEAD BOLT
SPLASHER PANEL ........................................... 1 ........... S/N 8500001TO 8500035
SPLASHER PANEL ........................................... 1 ........... S/N 8500036~
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500001TO 8500035
ACOUSTIC SHEET ........................................... 1 ........... S/N 8500036~
HEX, HEAD BOLT ............................................. 4 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ............................................. 2 ........... S/N 8500041~
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DOOR HANDLE ASSY.
SEAL RUBBER
MACHINE SCREW
HEX, NUT
1
1
1
1
1
1
1
1
4
4
16
16
6
5
11
HINGE
HINGE
WASHER
HEX, HEAD BOLT ........................................... 26 ........... S/N 8500001TO 8500040
HEX, HEAD BOLT ........................................... 26 ........... S/N 8500041~
STOPPER
MACHINE SCREW
CAP
8
8
13
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 77
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DCA-125USJ — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 78 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
QTY.
1
1
3
2
1
4
3
4
3
1
4
1
1
1
2
1
REMARKS
0229200870
0229201130
0229201240
0228900660
0229201070
0229200125
0228901165
0228900925
0228901105
0228900565
0228900945
0228800505
0229201200
0228800635
0228800970
0228800595
0228100640
0228100370
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
9
10
11
12
13
14
15
16
17
18
2
2
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 79
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DCA-125USJ — NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
PAGE 80 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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DCA-125USJ — NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO.
1
2
3
4
5
5
6
7
PART NO.
PART NAME
QTY.
REMARKS
M1550000204
M1550000703
M3550000004
M3550001603
M3550001703
M3550002003
M3550001803
M9500000004
M9500100004
M9500300004
M9500300104
M9500500004
M9503000004
M9503000103
M9503100004
M9503200004
M9510000004
M9510100004
M9510100403
M9520000004
M9520000104
M9520000204
M9520000504
M9520100004
M9520100204
M9520100304
M9520100404
M9520100503
M9520100603
M9520200003
M9520200104
M9512200004
M9510200304
M3560102004
M3560102103
M3560102204
M3560102303
M3560102403
M3560102504
0600500092
DECAL, NOTE ................................................... 1 ........... M15000020
DECAL, AUXILARY OUTPUT............................ 1 ........... M15000070
DECAL, NOTE ................................................... 1 ........... M35000000
DECAL, GENERATOR CONTROL ..................... 1 ........... M35000160
DECAL, ENGINE OPERATING, M35000170..... 1 ........... S/N 8500001TO 8500040
DECAL, ENGINE OPERATING, M35000200..... 1 ........... S/N 8500041~
DECAL, OPERATING PROCEDURES .............. 1 ........... M35000180A
DECAL, OIL DRAIN PLUG ................................ 1 ........... M90000000
DECAL, WATER................................................. 1 ........... M90010000
DECAL, NEGATIVE........................................... 1 ........... M90030000
DECAL, POSITIVE ........................................... 1 ........... M90030010
DECAL, DIESEL FUEL ..................................... 1 ........... M90050000
DECAL, WARNING MOVING PARTS ................ 2 ........... M90300000
DECAL, WATER OIL CHECK ............................ 1 ........... M90300010
DECAL, WARNING HOT COOLANT .................. 1 ........... M90310000
DECAL, WARNING ENGINE EXHAUST ........... 1 ........... M90320000
DECAL, FLUID DRAIN ...................................... 1 ........... M91000000
DECAL, CAUTION HOT PARTS ........................ 1 ........... M91010000
DECAL, CAUTION ............................................. 1 ........... M91010040
DECAL, GROUND ............................................. 1 ........... M92000000
DECAL, AMMETER CHANGE-OVER SW......... 1 ........... M92000010
DECAL, VOLTMETER CHANGE-OVER SW. ..... 1 ........... M92000020
DECAL, START CONTACT................................ 1 ........... M92000050
DECAL, WARNING ELECTRIC HAZARD .......... 2 ........... M92010000
DECAL, CAUTION ............................................. 1 ........... M92010020A
DECAL, SAFETY INSTRUCTIONS ................... 1 ........... M92010030
DECAL, DANGER HIGHVOLTAGE ................... 1 ........... M92010040
DECAL,WARNING ............................................ 1 ........... M92010050
DECAL, CAUTION ............................................. 2 ........... M92010060
DECAL, CONNECTION OF OUTPUT CABLE .. 1 ........... M92020000
DECAL, OVER CURRENT RELAY .................... 1 ........... M92020010
DECAL, MQ....................................................... 1 ........... M91220000
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
39A
40
DECAL, MQ POWER
STRIPE
STRIPE, WHISPERWATT
STRIPE
STRIPE, 125
STRIPE, 125
STRIPE
PLATE, MQ POWER ......................................... 1 ........... S/N 8400031~
MACHINE SCREW............................................ 4 ........... S/N 8400031~
DECAL, ENVIRONMENTALWARNIN6.............. 1 ........... S/N 8400031~
3
2
2
2
1
1
2
0021106016
M9510100304
1
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 81
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TERMS AND CONDITIONS OF SALE — PARTS
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
6. The following items are not returnable:
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
LIMITATIONS OF SELLER’S LIABILITY
MINIMUM ORDER
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
RETURNED GOODS POLICY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
e. The list must include the name
and phone number of the person
requesting the RMA.
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
3. AcopyoftheReturnMaterialAuthorization
must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
PAGE 82 — DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11)
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NOTE PAGE
DCA-125USJ — OPERATION AND PARTS MANUAL — REV. #2 (01/27/11) — PAGE 83
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: pmastretta@cipsa.com.mx
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: jmartin@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, MULTIQUIP INC.
Multiquip Inc, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other
trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Your Local Dealer is:
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