Multiquip Portable Generator DCA125USI User Manual

OPERATION AND PARTS MANUAL  
®
MODEL DCA125USI  
60 HZ GENERATOR  
(ISUZU 4HK1X DIESEL ENGINE)  
Revision #1 (03/25/11)  
To find the latest revision of this  
publication, visit our website at:  
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.  
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REPORTING SAFETY DEFECTS  
If you believe that your vehicle has a defect that could cause a crash or could  
cause injury or death, you should immediately inform the National Highway  
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at  
1-800-421-1244.  
If NHTSA receives similar complaints, it may open an investigation, and if it  
finds that a safety defect exists in a group of vehicles, it may order a recall and  
remedy campaign. However, NHTSA cannot become involved in individual  
problems between you, your dealer, or Multiquip.  
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at  
write to:  
Administrator  
NHTSA  
1200 New Jersey Avenue S.E.  
Washington, DC 20590  
You can also obtain information about motor vehicle safety from  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 3  
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TABLE OF CONTENTS  
DCA125USI 60 Hz Generator  
Proposition 65 Warning ........................................... 2  
Reporting Safety Defects......................................... 3  
Table Of Contents.................................................... 4  
Parts Ordering Procedures...................................... 5  
Safety Information .............................................. 6-11  
Specifications ........................................................ 12  
Dimensions............................................................ 13  
Installation ............................................................. 14  
Installation ............................................................. 15  
General Information............................................... 16  
Major Components ................................................ 17  
Generator Control Panel........................................ 18  
Engine Operating Panel.................................... 20-21  
Output Terminal Panel Familiarization .............. 22-24  
Load Application.................................................... 25  
Generator Outputs................................................. 26  
Generator Outputs/Gauge Reading....................... 27  
Output Terminal Panel Connections ................. 28-29  
Inspection/Setup............................................... 30-33  
Generator Start-Up Procedure ........................ 34-35  
Generator Shut-Down Procedures ........................ 36  
Maintenance..................................................... 37-40  
Trailer Maintenance .......................................... 41-44  
Trailer WirIng Diagram........................................... 45  
Generator Wiring Diagram..................................... 46  
Engine Wiring Diagram.......................................... 47  
Controller Wiring Diagram ..................................... 48  
Troubleshooting (Generator).................................. 49  
Troubleshooting (Diagnostic Lamp)....................... 50  
Explanation Of Code In Remarks Column............. 52  
Suggested Spare Parts ......................................... 53  
Component Drawings  
Generator Assembly......................................... 54-55  
Control Box Assembly ...................................... 56-59  
Engine and Radiator Assembly ........................ 60-65  
Output Terminal Assembly................................ 66-66  
Battery Assembly.............................................. 68-69  
Muffler Assembly.............................................. 70-71  
Fuel Tank Assembly ......................................... 72-73  
Enclosure Part 1 Assembly .............................. 74-77  
Enclosure Part 2 Assembly .............................. 78-81  
Rubber Seals Assembly ................................... 82-83  
Nameplate and Decals Assembly .................... 84-87  
Terms And Conditions Of Sale — Parts ................ 88  
PAGE 4 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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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!  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 5  
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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 6 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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SAFETY INFORMATION  
NEVER use accessories or attachments that are not  
recommended by MQ Power 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  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 7  
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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  
hours to burn off the accumulated unburned fuel.  
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.  
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 8 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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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:  
• Connect and test electric brake operation.  
NEVER use fuel as a cleaning agent.  
• Secure 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  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 9  
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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  
duringoperationcancauseelectrocution,  
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 10 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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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  
ALWAYSwearsafetyglasseswhenhandling  
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  
environmenttoavoidtheriskofadangerousconcentration  
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.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 11  
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SPECIFICATIONS  
Table 1. Generator Specifications  
DCA125USI  
Model  
Type  
Revolving field, self ventilated,  
open protected type synchronous generator  
Armature Connection  
Phase  
Star with Neutral  
3
Zigzag  
1
Standby Output  
Prime Output  
110 kW (137.5 kVA)  
100 kW (100 kVA)  
79 kW  
72 kW  
3Ø Voltage (L-L/L-N)  
Voltage Selector Switch at 3Ø 240/139  
208Y/120, 220Y/127,  
240Y/139  
N/A  
N/A  
3Ø Voltage (L-L/L-N)  
Voltage Selector Switch at 3Ø 480/277  
416Y/240, 440Y/254,  
480Y/277  
1Ø Voltage (L-L/L-N)  
Voltage Selector Switch at 1Ø 240/120  
N/A  
0.8  
240/120  
1.0  
Power Factor  
Frequency  
60 Hz  
Speed  
1800 rpm  
Aux. AC Power  
Aux. Voltage/Output  
Single Phase, 60 Hz  
120V/4.8 Kw (2.4 kW x 2)  
Sound Level dB (A)  
Full Load at 23 ft. (7.0 Meters)  
65  
Dry Weight  
Wet Weight  
5,689 lbs. (2,580 kg)  
7,012 lbs. (3,180 kg)  
Table 2. Engine Specifications  
Model  
Type  
ISUZU 4HK1XYGD-03 Tier 3  
4 cycle, water-cooled, direct injection, turbocharged,  
air to air intercooled  
No. of Cylinders  
Bore x Stroke  
4 cylinders  
4.53 in. x 4.92 in. (115 mm x 125 mm)  
317 cu. in. (5193 cc)  
152 HP/1800 RPM  
Electric  
Displacement  
Rated Output  
Starting  
Coolant Capacity  
Lube Oil Capacity  
Fuel Type  
5.2 gal. (19.7 liters)  
6.1 gal. (23.4 liters)  
#2 Diesel Fuel  
Fuel Leak Warning Capacity  
Fuel Tank Capacity  
42.3gal. (160 liters)  
169 gal. (640 liters)  
7.3 gal. (27.6 L)/hr at full  
load  
5.7 gal. (21.7 L)/hr at 3/4  
load  
Fuel Consumption  
Battery  
4.0 gal. (15.1 L)/hr at 1/2  
load  
2.4 gal. (9.1 L)/hr at 1/4  
load  
12V-128 Ah x 1  
PAGE 12 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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DIMENSIONS  
Figure 1. Dimensions  
Table 3. Dimensions  
Reference  
Letter  
Dimension in. (mm)  
Reference Letter  
Dimension in. (mm)  
A
B
C
D
38.20 in. (970 mm.)  
37.00 in. (940 mm.)  
36.20 in. (920 mm.)  
37.00 in. (940 mm.)  
F
G
H
120.10 in. (3,050 mm.)  
73.00 in. (1,855 mm.)  
48.80 in. (1,200 mm.)  
E
3620 in. (920 mm.)  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 13  
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INSTALLATION  
Figure 2. Typical Generator Grounding Application  
PAGE 14 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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INSTALLATION  
OUTDOOR INSTALLATION  
GENERATOR GROUNDING  
Install the generator in a area that is free of debris,  
bystanders, and overhead obstructions. Make sure the  
generator is on secure level ground so that it cannot slide  
or shift around. Also install the generator in a manner so  
that the exhaust will not be discharged in the direction of  
nearby homes.  
To guard against electrical shock and possible damage to  
the equipment, it is important to provide a good EARTH  
ground.  
Article 250 (Grounding) of the National Electrical Code  
(NEC) provides guide lines for proper grounding and  
specifies that the cable ground shall be connected to the  
grounding system of the building as close to the point of  
cable entry as practical.  
The installation site must be relatively free from moisture  
and dust.All electrical equipment should be protected from  
excessive moisture. Failure to do will result in deterioration  
of the insulation and will result in short circuits and  
grounding.  
NEC articles 250-64(b) and 250-66 set the following  
grounding requirements:  
1. Use one of the following wire types to connect the  
generator to earth ground.  
Foreign materials such as dust, sand, lint and abrasive  
materials have a tendency to cause excessive wear to  
engine and alternator parts.  
a. Copper - 10 AWG (5.3 mm2)  
b. Aluminum - 8 AWG (8.4 mm2)  
CAUTION  
Pay close attention to ventilation when operating the  
generator inside tunnels and caves.The engine exhaust  
contains noxious elements. Engine exhaust must be  
routed to a ventilated area.  
2. When grounding the generator (Figure 2) connect the  
ground cable between the lock washer and the nut on  
the generator and tighten the nut fully. Connect the  
other end of the ground cable to earth ground.  
3. NEC article 250-52(c) specifies that the earth ground rod  
should be buried a minimum 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.  
NOTICE  
When connecting the generator to any buildings  
electrical system ALWAYS consult with a licensed  
electrician.  
MOUNTING  
The generator must be mounted on a solid foundation (such  
as concrete) and set firmly on the foundation to isolate  
vibration of the generator when it is running.The generator  
must set at least 6 inches above the floor or grade level (in  
accordance to NFPA 110, Chapter 5-4.1).DO NOT remove  
the metal skids on the bottom of the generator. They are  
to resist damage to the bottom of the generator and to  
maintain alignment.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 15  
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GENERAL INFORMATION  
GENERATOR  
OPEN DELTA EXCITATION SYSTEM  
This MQ Power Model generator (Figure 3) is a high quality  
portable (requires a trailer for transport) power source for  
telecom sites, lighting facilities, power tools, submersible  
pumps and other industrial and construction machinery.  
This generator is equipped with the state of the art “Open-  
Delta” excitation system. The open delta system consist  
of an electrically independent winding wound among  
stationary windings of the AC output section.  
There are four connections of the open delta A, B, C and  
D. During steady state loads, the power from the voltage  
regulator is supplied from the parallel connections of A to  
B, A to D, and C to D. These three phases of the voltage  
input to the voltage regulator are then rectified and are the  
excitation current for the exciter section.  
ENGINE OPERATING PANEL  
The “Engine Operating Panel” is provided with the following:  
Tachometer  
Water Temperature Gauge  
Warning Lamp  
Pre-Heat 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.  
Oil Pressure Gauge  
Charging Ammeter Gauge  
Fuel Level Gauge  
Fuel Leak Detection Lamp  
Panel Light/Panel Light Switch  
ECU Controller  
Engine Speed Switch  
The connections of the AVR to the AC output windings are  
for sensing only. No power is required from these windings.  
The open-delta design provides virtually unlimited excitation  
current, offering maximum motor starting capabilities.The  
excitation does not have a “fixed ceiling” and responds  
according the demands of the required load.  
Warning Lamp (Diagnostic Lamp)  
GENERATOR CONTROL PANEL  
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  
3-Pole, 350 amp Main Circuit Breaker  
“Control Box” (located behind the Gen. Control Panel)  
• Automatic Voltage Regulator  
• Current Transformer  
The DCA125USI is powered by a 4 cylinder, water cooled,  
direct injection, turbocharged ISUZU 4HK1X diesel engine.  
This engine is designed to meet every performance  
requirement for the generator.ReferenceTable 2 for engine  
specifications.  
In keeping with MQ Power’s policy of constantly improving  
its products, the specifications quoted herein are subject  
to change without prior notice.  
• Over-Current Relay  
• Starter Relay  
ELECTRIC GOVERNOR SYSTEM  
• Voltage Selector Switch  
• Diagnostic Switch  
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%.  
OUTPUT TERMINAL PANEL  
The “Output Terminal Panel” is provided with the following:  
Three 120/240V output receptacles (CS-6369), 50A  
Three auxiliary circuit breakers, 50A  
Two 120V output receptacles (GFCI), 20A  
Two GFCI circuit breakers, 20A  
Five output terminal lugs (3Ø power)  
Battery Charger (Optional)  
EXTENSION CABLES  
When electric power is to be provided to various tools or  
loads at some distance from the generator, extension cords  
are normally used. Cables should be sized to allow for  
distance in length and amperage so that the voltage drop  
between the generator and point of use (load) is held to  
a minimum. Use the cable selection chart (Table 6) as a  
guide for selecting proper extension cable size.  
Jacket Water Heater (Optional)  
Low Coolant Level Switch  
PAGE 16 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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MAJOR COMPONENTS  
Table 4. 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  
Engine Operating Panel Assembly  
Generator Control Panel Assembly  
Figure 3. Major Components  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 17  
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GENERATOR CONTROL PANEL  
Figure 4. Generator Control Panel  
The definitions below describe the controls and functions  
of the Generator Control Panel (Figure 4).  
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.  
1. Main Circuit Breaker—This three-pole, 350A main  
breaker is provided to protect the the U,V, and W  
Output Terminal Lugs from overload.  
The Control Box is equipped with the following major  
components:  
2. Voltage Regulator Control — Allows 15% manual  
adjustment of the generator’s output voltage.  
Over-Current Relay  
3. Ammeter Change-Over Switch This switch allows  
the AC ammeter to indicate the current flowing to the  
load connected to any phase of the output terminals,  
or to be switched off. This switch does not effect the  
generator output in any fashion, it is for current reading  
only.  
Automatic Voltage Regulator (AVR)  
Starter Relay  
Current Transformer  
Voltage Selector Switch  
Main Circuit Breaker  
4. Voltmeter Change-Over Switch This switch allows  
the AC voltmeter to indicate phase to phase voltage  
between any two phases of the output terminals or to  
be switched off.  
NOTICE  
Remember the overcurrent relay monitors the current  
flowing from the U,V, and W Output Terminal Lugs  
to the load.  
5. Frequency Meter — Indicates the output frequency  
in hertz (Hz). Normally 60 Hz.  
In the event of a short circuit or over current condition,  
it will automatically trip the 350 amp main breaker.  
6. AC Ammeter — Indicates the amount of current the  
load is drawing from the generator per leg selected by  
the ammeter phase-selector switch.  
To restore power to the OutputTerminal Panel, press  
the reset button on the overcurrent relay and place the  
main circuit breaker in the closed position (ON).  
7. ACVoltmeter — Indicates the output voltage present  
at the U,V, and W Output Terminal Lugs.  
PAGE 18 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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NOTES  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 19  
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ENGINE OPERATING PANEL  
Figure 5. Engine Operating Panel  
PAGE 20 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENGINE OPERATING PANEL  
The definitions below describe the controls and functions  
of the Engine Operating Panel (Figure 5).  
and all major faults will shutdown the generator.During  
cranking cycle, the ECU will attempt to crank the engine  
for 10 seconds before disengaging.  
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.  
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.  
2. Panel Light Switch — When activated will turn on  
control panel light.  
3. Preheat Lamp — As the engine cranks, this lamp  
will illuminate to indicate automatic preheating of  
the engine glow plugs. When the lamp turns off, this  
indicates that the preheat cycle is complte and the  
engine will start automatically.  
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.  
4. Warning Lamp (Diagnostic Lamp) — When lit  
indicates a that a failure has occured in the engine  
control system.  
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.  
5. Fuel Leak Detection Lamp This lamp will illuminate  
when a leak in the fuel tank containment enclosure is  
detected.  
6. Engine Speed Switch — This switch controls the  
speed of the engine (low/high).  
If the generator is to be connected to a building’s  
AC power source via an automatic transfer switch  
(isolation), place the switch in the AUTO position.In this  
position, should an outage occur, the automatic transfer  
switch (ATS) will start the generator automatically  
via the generator’s auto-start contacts connected to  
the ATS’s start contacts. Please refer to your ATS  
installation manual for further instructions for the  
correct installation of the auto-start contacts of the  
generator to the ATS.  
7. Oil Pressure Gauge — During normal operation this  
gauge should read between 42 ~71 psi.(290~490 kPa).  
When starting the generator the oil pressure may read  
a little higher, but after the engine warms up the oil  
pressure should return to the correct pressure range.  
8. WaterTemperature Gauge — During normal operation  
this gauge be should read between 167°~203°F (75°  
~95°C  
9. 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.  
B. Low Oil Pressure — Indicates the engine pressure  
has fallen below 15 psi (103 kPa). The oil pressure is  
detected using variable resistive values from the oil  
pressure sending unit.This is considered a major fault.  
10. Fuel Gauge — Indicates amount of diesel fuel  
available.  
C. High Coolant Temperature — Indicates the engine  
temperature has exceeded 230°F (110°C).The engine  
temperature is detected using variable resistive values  
from the temperature sending unit. This is considered  
a major fault.  
11. 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.  
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.  
12. Auto START/STOP Engine  
Controller (ECU) 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  
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.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 21  
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OUTPUT TERMINAL PANEL FAMILIARIZATION  
OUTPUT TERMINAL PANEL  
OUTPUT TERMINAL FAMILIARIZATION  
The Output Terminal Panel (Figure 6) shown below is  
located on the right-hand side (left from control panel) of  
the generator. Lift up on the cover to gain access to  
receptacles and terminal lugs.  
The “Output Terminal Panel ” (Figure 6) is provided with  
the following:  
Three 120/240V output receptacles @ 50 amp  
Three Circuit Breakers @ 50 amps  
NOTICE  
Two 120V GFCI receptacles @ 20 amp  
Two GFCI Circuit Breakers @ 20 amps  
Five Output Terminal Lugs ( U, V, W, O, Ground)  
Terminal legs “Oand “Groundare considered bonded  
grounds.  
Figure 6. Output Terminal Panel  
PAGE 22 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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OUTPUT TERMINAL PANEL FAMILIARIZATION  
Each auxiliary receptacle is protected by a 50 amp circuit  
breaker. These breakers are located directly above the  
GFCI receptacles. Remember the load output (current) on  
all three receptacles is dependent on the load requirements  
of the output terminal lugs.  
120 VAC GFCI Receptacles  
There are two 120 VAC, 20 amp GFCI (Duplex Nema  
5-20R) receptacles provided on the output terminal panel.  
These receptacles can be accessed in any voltage  
selector switch position.Each receptacle is protected by a  
20 amp circuit breaker.These breakers are located directly  
above the GFCI receptacles. Remember the load output  
(current) of both GFCI receptacles is dependent on the load  
requirements of the U, V, and W output terminal lugs.  
Turn the voltage regulator control knob (Figure 9) on the  
control panel to obtain the desired voltage.Turning the knob  
clockwise will increase the voltage, turning the knob  
counter-clockwise will decrease the voltage.  
Pressing the reset button resets the GFCI receptacle after  
being tripped. Pressing the test button (Figure 7) in the  
center of the receptacle will check the GFCI function. Both  
receptacles should be tested at least once a month.  
Figure 9. Voltage Regulator Control Knob  
Removing the Plastic Face Plate (Hard Wire Hookup  
Panel)  
The output terminal lugs are protected by a plastic face  
plate cover (Figure 10). 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 7. G.F.C.I. Receptacle  
Twist Lock Dual Voltage 120/240 VAC Receptacles  
There are three 120/240V, 50 amp auxiliary twist-lock (CS-  
6369) receptacles (Figure 8) provided on the output  
terminal panel. These receptacles can only be accessed  
when the voltage selector switch is placed in the single-  
phase 240/120 position.  
Figure 10. Plastic Face Plate  
(Output Terminal Lugs)  
Figure 8. 120/240V Twist-Lock  
Auxiliary Receptacles  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 23  
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OUTPUT TERMINAL PANEL FAMILIARIZATION  
Connecting Loads  
Over Current Relay  
Loads can be connected to the generator by the output  
terminal lugs or the convenience receptacles (Figure 11).  
Make sure to read the operation manual before attempting  
to connect a load to the generator.  
An over current relay (Figure 12) is connected to the main  
circuit breaker. In the event of an overload, both the circuit  
breaker and the over current relay may trip. If the circuit  
breaker can not be reset, the reset button on the over  
current relay must be pressed. The over current relay is  
located in the control box.  
To protect the output terminals from overload, a 3-pole, 350  
amp main circuit breaker is provided. Make sure to switch  
ALL circuit breakers to the OFF position prior to starting  
the engine.  
Figure 12. Over Current Relay  
Figure 11. Connecting Loads  
PAGE 24 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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LOAD APPLICATION  
SINGLE PHASE LOAD  
THREE PHASE LOAD  
Always be sure to check the nameplate on the generator  
and equipment to insure the wattage, amperage, frequency,  
and voltage requirements are satisfactorily supplied by the  
generator for operating the equipment.  
When calculating the power requirements for 3-phase  
power use the following equation:  
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.  
NOTICE  
If 3Ø load (kVA) is not given on the equipment  
nameplate, approximate 3Ø load may be determined  
by multiplying voltage by amperage by 1.732.  
NOTICE  
If wattage is not given on the equipment’s name plate,  
approximate wattage may be determined by multiplying  
nameplate voltage by the nameplate amperage.  
NOTICE  
Motors and motor-driven equipment draw much greater  
current for starting than during operation.  
WATTS = VOLTAGE x AMPERAGE  
An inadequate size connecting cable which cannot carry the  
required load can cause a voltage drop which can burn out  
the appliance or tool and overheat the cable. See Table 6.  
The power factor of this generator is 0.8.SeeTable 5 below  
when connecting loads.  
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.  
Table 5. Power Factor By Load  
Type of Load  
Power Factor  
Single-phase induction motors  
0.4-0.75  
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.  
Electric heaters, incandescent lamps  
Fluorescent lamps, mercury lamps  
1.0  
0.4-0.9  
Electronic devices, communication  
equipment  
When connecting an electric drill or other power tools,  
pay close attention to the required starting current  
capacity.  
1.0  
0.8  
Common power tools  
When connecting ordinary power tools, a capacity of up to  
the generating set’s rated output (kW) multiplied by 0.8 can  
be used.  
Table 6. Cable Selection (60 Hz, Single Phase Operation)  
Load in Watts  
Maximum Allowable Cable Length  
Current  
in  
Amperes  
At 100  
Volts  
At 200  
Volts  
#10 Wire #12 Wire #14 Wire #16 Wire  
DANGER  
2.5  
5
300  
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.  
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.  
600  
1200  
1800  
2400  
3600  
4800  
7.5  
10  
15  
20  
900  
1200  
1800  
2400  
50 ft.  
CAUTION: Equipment damage can result from low voltage  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 25  
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GENERATOR OUTPUTS  
GENERATOR OUTPUT VOLTAGES  
Generator Amperage  
A wide range of voltages are available to supply voltage for  
many different applications.Voltages are selected by using  
the voltage selector switch (Figure 13).To obtain some of  
the voltages as listed in Table 7 (see below) will require a  
fine adjustment using the voltage regulator (VR) control  
knob located on the control panel.  
Table 8 shows the maximum amps the generator can  
provide. DO NOT exceed the maximum amps as listed..  
Table 8. Generator Maximum Amps  
Rated Voltage  
Maximum Amps  
277.8 amps (4 wire)  
301A x 2 (Zigzag)  
1Ø 120 Volt  
Voltage Selector Switch  
138.9 amps (4 wire)  
301A (Zigzag)  
1Ø 240 Volt  
The voltage selector switch (Figure 13) is located above  
the output terminal panel’s Hard Wire Hook-up Panel. It  
has been provided for ease of voltage selection.  
3Ø 240 Volt  
3Ø 480 Volt  
301 amps  
150 amps  
GFCI Receptacle Load Capability  
The load capability of the GFCI receptacles is directly  
related to the voltage being supplied at either the output  
terminals or the 2 twist lock auxiliary receptacles.  
Table 9 and Table 10 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 receptacles.  
Figure 13. Voltage Selector Switch  
Voltage Selector Switch Locking Button  
To lock the voltage selector switch, press and hold the  
red button located at the bottom of the switch. While  
holding the red button down, insert a pad lock into the hole  
next to the button to retain it in the inward locked position.  
When the lock is removed, the red button is spring loaded  
and will return to its normal outward unlocked position.  
Table 9. 1Ø GFCI Receptacle Load Capacity  
KW in Use  
Twist Lock (C6369)  
Available Load  
Current (Amps)  
GFCI Duplex  
5-20R 120V  
1Ø 240/120V  
72.0  
70.8  
0 amps/receptacle  
5 amps/receptacle  
69.6  
68.4  
67.2  
10 amps/receptacle  
15 amps/receptacle  
20 amps/receptacle  
CAUTION  
NEVER change the position of the voltage selector  
switch while the engine is running. ALWAYS place  
circuit breaker in the OFF position before selecting  
voltage.  
Table 10. GFCI Receptacle Load Capacity  
KVA in Use  
(UVWO Terminals)  
Available Load  
Current (Amps)  
Table 7. Voltages Available  
GFCI Duplex  
5-20R 120V  
3Ø 240/480V  
UVWO Output  
Terminal Lugs  
Voltage Selector Switch  
3-Phase 240/139V Position  
Voltage Selector Switch  
3-Phase 480/270V Position  
0 amps/receptacle  
5 amps/receptacle  
125  
121  
208V  
120V  
220V  
127V  
240V  
139V  
416V  
240V  
440V  
254V  
480V  
277V  
Line-Line  
Line-Neutral  
10 amps/receptacle  
15 amps/receptacle  
20 amps/receptacle  
117  
113  
108  
Voltage Selector Switch Single-Phase 240/120V Position  
Line-Neutral/  
Line-Line  
120V  
Line-Neutral  
240V  
Line-Line  
N/A  
N/A  
N/A  
N/A  
PAGE 26 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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GENERATOR OUTPUTS/GAUGE READING  
HOW TO READ THE AC AMMETER AND AC  
VOLTAGE GAUGES  
AC Ammeter Gauge Reading  
Place the AC Ammeter Change-Over Switch (Figure 17)  
in the U position and observe the current reading (load  
drain) on the U terminal as indicated on the AC Ammeter  
Gauge (Figure 18). This process can be repeated for  
terminals V and W.  
The AC ammeter and AC voltmeter gauges are controlled  
by the AC ammeter and AC voltmeter change-over  
switches.  
Both of these switches are located on the control panel and  
DO NOT effect the generator output. They are provided to  
help observe how much power is being supplied, produced  
at the UVWO terminals lugs.  
Before taking a reading from either gauge, set the Voltage  
Selector Switch (Figure 14) to the position which produces  
the required voltage (For example, for 3Ø 240V, choose  
the center 3Ø 240/139V position on the voltage selector  
switch)  
Figure 17. AC Ammeter  
Change-Over Switch  
Figure 18. AC Ammeter  
(Amp Reading on U Lug)  
NOTICE  
The ammeter gauge will only show a reading when  
the Output Terminal Lugs are connected to a load  
and in use.  
Figure 14. Voltage Selector Switch  
240/139V 3Ø Positio  
NOTICE  
For 3Ø 208V/1Ø,120V, place the Voltage Selector  
Switch in the 3 Phase 240/139 position.  
AC Voltmeter Gauge Reading  
Place the ACVoltmeter Change-Over Switch (Figure 15)  
in theW-U position and observe the phase to phase voltage  
reading between the W and U terminals as indicated on  
the AC Voltmeter Gauge (Figure 16)  
Figure 15. AC Voltmeter  
Change-Over Switch  
Figure 16. AC Voltmeter  
Gauge  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 27  
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OUTPUT TERMINAL PANEL CONNECTIONS  
3. Turn the voltage regulator knob (Figure 21) clockwise  
to increase voltage output, turn counterclockwise to  
UVWO TERMINAL OUTPUT VOLTAGES  
Various output voltages can be obtained using the UVWO  
output terminal lugs. The voltages at the terminals are  
dependent on the position of the Voltage Selector Switch  
and the adjustment of the Voltage Regulator Control  
Knob.  
decrease voltage output. Use voltage regulator  
adjustment knob whenever fine tuning of the output  
voltage is required.  
Remember the voltage selector switch determines the  
range of the output voltage. The voltage regulator (VR)  
allows the user to increase or decrease the selected  
voltage.  
Figure 21. Voltage Regulator Knob  
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages  
3Ø-240/139 UVWO Terminal Output Voltages  
1. Place the voltage selector switch in the 3Ø 240/139  
position as shown in Figure 22.  
1. Place the voltage selector switch in the 3Ø 240/139  
position as shown in Figure 19.  
Figure 22. Voltage Selector Switch  
3Ø-240/139V Position  
Figure 19. Voltage Selector Switch  
3Ø-240/139V Position  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 23.  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 20.  
Figure 23. UVWO Terminal Lugs  
3Ø-208/1Ø-120V Connections Connections  
NOTICE  
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.  
Figure 20. UVWO Terminal Lugs  
3Ø-240/139V Connections  
PAGE 28 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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OUTPUT TERMINAL PANEL CONNECTIONS  
3Ø-480/277V UVWO Terminal Output Voltages  
1Ø-240/120V UVWO Terminal Output Voltages  
1. Place the voltage selector switch in the 3Ø 480/277  
position as shown in Figure 24.  
1. Place the voltage selector switch in the 1Ø 240/120  
position as shown in Figure 26.  
Figure 24. Voltage Selector Switch  
3Ø-480/277V Position  
Figure 26. Voltage Selector Switch  
1Ø-240/120V Position  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 25.  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 27.  
Figure 25. UVWO Terminal Lugs  
3Ø-480/277V Connections  
Figure 27. UVWO Terminal Lugs  
1Ø-240/120V Connections  
3. Turn the voltage regulator knob (Figure 21) clockwise  
to increase voltage output, turn counterclockwise  
to decrease voltage output. Use voltage regulator  
adjustment knob whenever fine tuning of the output  
voltage is required.  
3. Turn the voltage regulator knob (Figure 21) clockwise  
to increase voltage output, turn counterclockwise to  
decrease voltage output. Use voltage regulator  
adjustment knob whenever fine tuning of the output  
voltage is required.  
NOTICE  
ALWAYS make sure that the connections to the UVWO  
terminals are secure and tight.The possibility of arcing  
exists, that could cause a fire.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 29  
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INSPECTION/SETUP  
CIRCUIT BREAKERS  
FUEL CHECK  
To protect the generator from an overload, a 3-pole, 350  
amp, main circuit breaker is provided to protect the U,V,  
and W Output Terminals from overload. In addition two  
single-pole, 20 amp GFCI circuit breakers are provided to  
protect the GFCI receptacles from overload.Three 50 amp  
load circuit breakers have also been provided to protect the  
auxiliary receptacles from overload. Make sure to switch  
ALL circuit breakers to the OFF position prior to starting  
the engine.  
DANGER  
Fuel spillage on a hot engine can cause  
a fire or explosion.If fuel spillage occurs,  
wipe up the spilled fuel completely to  
prevent fire hazards. NEVER smoke  
around or near the generator.  
Refilling the Fuel System  
LUBRICATION OIL  
CAUTION  
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 28) on the dipstick. See Table 11 for  
proper selection of engine oil.  
ONLY properly trained personnel who have read  
and understand this section should refill the fuel tank  
system.  
This generator has an internal fuel tank located inside  
the trailer frame and may also be equipped with an  
environmental fuel tank (Figure 29). ALWAYS fill the fuel  
tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel  
tanks beyond their capacities.  
Figure 28. Engine Oil Dipstick  
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.  
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 ISUZU Engine Owner’s Manual.Oil should  
be warm before draining.  
Other types of motor oils may be substituted if they meet  
the following requirements:  
API Service Classification CC/SC  
API Service Classification CC/SD  
API Service Classification CC/SE  
API Service Classification CC/SF  
Table 11. Recommended Motor Oil  
Figure 29. Internal Fuel Tank System  
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INSPECTION/SETUP  
2. Open cabinet doors on the “right side” of the generator  
(from generator control panel position). Remove fuel  
cap and fill tank (Figure 31).  
Refueling Procedure:  
WARNING  
Diesel fuel and its vapors are dangerous  
to your health and the surrounding  
environment. Avoid skin contact and/or  
inhaling fumes.  
1. LevelTanks — 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 30).  
CAUTION  
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 31. 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 32).  
Figure 30. Only Fill on Level Ground  
Figure 32. Full Fuel Tank  
NOTICE  
CAUTION  
ONLY use #2 diesel fuel when refueling.  
DO NOT OVERFILL fuel system. Leave room for fuel  
expansion. Fuel expands when heated (Figure 33).  
Figure 33. Fuel Expansion  
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INSPECTION/SETUP  
COOLANT (ANTIFREEZE/SUMMER COOLANT/  
WATER)  
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.  
ISUZU recommends ISUZU antifreeze/summer coolant for  
use in their engines, which can be purchased in concentrate  
(and mixed with 50% demineralized water) or pre-diluted.See  
the ISUZU Engine Owner’s Manual for further details.  
AIR CLEANER  
WARNING  
Periodic cleaning/replacement is necessary. Inspect it in  
accordance with the ISUZU Engine Owner’s Manual.  
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.  
FAN BELT TENSION  
A slack fan belt may contribute to overheating, or to  
insufficient charging of the battery. Inspect the fan belt for  
damage and wear and adjust it in accordance with the  
ISUZU 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 12 for engine, radiator, and recovery tank coolant  
capacities.Make sure the coolant level in the recovery tank  
is always between the “H” and the “Lmarkings.  
The fan belt tension is proper if the fan belt bends 10 to 15  
mm (Figure 34) when depressed with the thumb as shown  
below.  
Table 12. Coolant Capacity  
Engine and Radiator  
Reserve Tank  
5.2 gal (19.7 liters)  
TBD  
Operation in Freezing Weather  
Figure 34. Fan Belt Tension  
When operating in freezing weather, be certain the proper  
amount of antifreeze (Table 13) has been added.  
CAUTION  
NEVER place hands near the belts or fan  
while the generator set is running.  
Table 13. Anti-Freeze  
Operating Temperatures  
Freezing Point  
Vol %  
Anti-Freeze  
°C  
°F  
50  
-37  
-34  
NOTICE  
When the antifreeze is mixed with water, the antifreeze  
mixing ratio must be less than 50%.  
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INSPECTION/SETUP  
When connecting battery do the following:  
BATTERY  
1. NEVER connect the battery cables to the battery  
terminals when the MPEC Control Switch is in either  
the MANUAL position. ALWAYS make sure that the  
MPEC Control Switch is in the OFF/RESET position  
when connecting the battery.  
This unit is of negative ground DO NOT connect in reverse.  
Always maintain battery fluid level between the specified  
marks. Battery life will be shortened, if the fluid level are  
not properly maintained. Add only distilled water when  
replenishment is necessary.  
2. Place a small amount of battery terminal treatment  
compound around both battery terminals. This will  
ensure a good connection and will help prevent  
corrosion around the battery terminals.  
DO NOT over fill. Check to see whether the battery  
cables are loose. Poor contact may result in poor starting  
or malfunctions. Always keep the terminals firmly  
tightened. Coating the terminals with an approved battery  
terminal treatment compound. Replace battery with only  
recommended type battery.  
NOTICE  
If the battery cable is connected incorrectly, electrical  
damage to the generator will occur.Pay close attention to  
the polarity of the battery when connecting the battery.  
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.  
CAUTION  
Before charging the battery with an external electric source,  
be sure to disconnect the battery cables.  
Inadequate battery connections may cause poor  
starting of the generator, and create other malfunctions.  
Battery Cable Installation  
ALWAYS be sure the battery cables (Figure 35) 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  
DO NOT put water directly on the alternator. Entry of water  
into the alternator can cause corrosion 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.  
Figure 35. Battery Connections  
If any hose (fuel or oil) lines are defective replace them  
immediately.  
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GENERATOR START-UP PROCEDURE  
BEFORE STARTING  
STARTING  
1. Place the voltage selector switch in the desired  
voltage position (Figure 38)..  
CAUTION  
The engine’s exhaust contains harmful emissions.  
ALWAYS have adequate ventilation when operating.  
Direct exhaust away from nearby personnel.  
WARNING  
NEVER manually start the engine with the main,GFCI or  
auxiliary circuit breakers in the ON (closed) position.  
1. Place the main, G.F.C.I., and aux. circuit breakers  
(Figure 36) in the OFF position prior to starting the  
engine.  
Figure 38. Voltage Selector Switch  
STARTING (MANUAL)  
1. Place the engine speed switch (Figure 39) in the LOW  
(down) position.  
Figure 39. Engine Speed Switch (Low)  
Figure 36. Main, Aux. and GFCI  
Circuit Breakers (OFF)  
2. Located in the control box is the engine controller  
diagnostic switch (Figure 40). Verify that this switch  
has been placed in the OFF position (down).  
2. Make sure the voltage change-over board has been  
configured for the desired output voltage.  
3. Connect the load to the receptacles or the output  
terminal lugs as shown in Figure 10. These load  
connection points can be found on the output terminal  
panel and the output terminal panel’s hard wire hookup  
panel.  
Figure 40. Diagnostic Switch  
3. Place the MPEC control switch in the MANUAL  
position to start the engine (Figure 41).  
4. Tighten terminal nuts securely to prevent load wires  
from slipping out.  
5. Close all engine enclosure doors (Figure 37).  
Figure 41. MPEC Control Switch  
(Manual Position)  
CORRECT  
INCORRECT  
Figure 37. Engine Enclosure Doors  
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GENERATOR START-UP PROCEDURE  
4. Depending on the temperature of the coolant (cold  
8. The generator’s AC-voltmeter (Figure 46) will display  
the generator’s output in VOLTS.  
weather conditions), the pre-heat lamp (Figure 42) will  
light (ON) and remain on until the pre-heating cycle has  
been completed. After completion of the pre-heating  
cycle, the light will go OFF and the engine will start up  
automatically.  
Figure 46. Voltmeter  
9. 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 42. Pre-Heat Lamp  
5. Once the engine starts, let the engine run for 1-2  
minutes. Listen for any abnormal noises. If any  
abnormalities exist, shut down the engine and correct  
the problem. If the engine is running smoothly, place  
the engine speed switch (Figure 43) in the HIGH (up)  
position.  
Figure 47. Voltage Adjust Control Knob  
10. 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 43. Engine Speed Switch (High)  
6. Verify that the Engine Running status LED on the  
MPEC unit (Figure 44) in ON (lit) after the engine has  
been started  
Figure 48. Ammeter (No Load)  
11. The engine oil pressure gauge (Figure 49) will indicate  
the oil pressure of the engine. Under normal operating  
conditions the oil pressure is approximately 42 to 71  
psi. (290~490 kPa).  
Figure 44. Engine Running LED (ON)  
7. The generator’s frequency meter (Figure 45) should be  
displaying the 60 cycle output frequency in HERTZ.  
Figure 49. Oil Pressure Gauge  
Figure 45. Frequency Meter  
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GENERATOR SHUT-DOWN PROCEDURES  
12. The coolant temperature gauge (Figure 50) will  
WARNING  
indicate the coolant temperature. Under normal  
operating conditions the coolant temperature should  
be between 167°~203°F (75°~95°C) (Green Zone).  
NEVER stop the engine suddenly except in an  
emergency.  
NORMAL SHUTDOWN PROCEDURE  
To shutdown the generator, use the following procedure:  
1. Place both the MAIN, GFCI and LOAD circuit breakers  
as shown in Figure 54 to the OFF position..  
Figure 50. Coolant Temperature Gauge  
13. 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 54. Main, GFCI and Load  
Circuit Breakers Off  
2. Place the engine speed switch (Figure 55) in the “LOW”  
(down) position..  
Figure 51. Engine Tachometer Gauge  
14. Place the main, GFCI, and aux. circuit breakers in the  
ON position (Figure 52).  
Figure 55. Ignition Switch (Normal)  
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 56) to the  
OFF/RESET position.  
Figure 52. Main, Aux. and GFCI  
Circuit Breakers (ON)  
15. Observe the generator’s ammeter (Figure 53) and  
verify it reads the anticipated amount of current with  
respect to the load. The ammeter will only display a  
current reading if a load is in use.  
Figure 56. MPEC Control Switch (Off/Reset)  
5. Verify that all status LEDs 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 occurred during operation.  
Figure 53. Ammeter (Load)  
EMERGENCY SHUTDOWN PROCEDURE  
16. The generator will run until manually stopped or an  
abnormal condition occurs.  
1. Place the MPEC Control Switch (Figure 56) in the  
OFF/RESET position.  
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MAINTENANCE  
10 Hrs  
DAILY  
1000  
Hrs  
Table 14. Inspection/Maintenance  
250 Hrs 500 Hrs  
Check Engine Fluid Levels  
Check Air Cleaner  
X
X
X
X
X
X
Check Battery Acid Level  
Check Fan Belt Condition  
Check for Leaks  
Check for Loosening of Parts  
Replace Engine Oil and Filter * 1  
Clean Air Filter  
X
X
Engine  
Check Fuel Filter/Water Separator Bowl  
Clean Unit, Inside and Outside  
Change Fuel Filter  
Clean Radiator and Check Coolant Protection Level*2  
Replace Air Filter Element * 3  
Check all Hoses and Clamps * 4  
Clean Inside of Fuel Tank  
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms  
X
Generator  
Check Rotor Rear Support Bearing  
X
1
*
*
*
*
Replace engine oil and filter at 100 hours, first time only.  
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.  
2
3
4
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).  
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,  
with no sags or dips that could collect moisture and/or oil.  
GENERAL INSPECTION  
Prior to each use, the generator should be cleaned and  
inspected for deficiencies. Check for loose, missing or  
damaged nuts, bolts or other fasteners. Also check for  
fuel, oil, and coolant leaks. Use Table 14 as a general  
maintenance guideline. Engine Side, refer to the Engine  
Instruction Manual.  
AIR CLEANER  
Every 250 hours: Remove air cleaner element (Figure 57)  
and clean the heavy duty paper element with light spray of  
compressed air. Replace the air cleaner as needed.  
Figure 57. Air Cleaner/Indicator  
NOTICE  
Air Cleaner with Dust Indicator  
The air filter should not be changed until the indicator  
reads “RED”. Dispose of old air filter. It may not be  
cleaned or reused.  
This indicator (Figure 57) 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.  
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MAINTENANCE  
If the engine is operating in very dusty or dry grass  
conditions, a clogged air cleaner will result.This can lead to  
a loss of power, excessive carbon buildup in the combustion  
chamber and high fuel consumption. Change air cleaner  
more frequently if these conditions exists.  
FUEL TANK INSPECTION  
In addition to cleaning the fuel tank, the following  
components should be inspected for wear:  
Rubber Suspension — look for signs of wear or  
deformity due to contact with oil. Replace the rubber  
suspension if necessary.  
FUEL ADDITION  
Add diesel fuel (the grade may vary according to season  
and locations).  
Fuel Hoses — inspect nylon and rubber hoses for signs  
of wear, deterioration and hardening.  
Removing Water from the Fuel Tank  
FuelTank Lining — inspect the fuel tank lining for signs  
of excessive amounts of oil or other foreign matter.  
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.  
Replacing Fuel Filter  
Replace the fuel filter cartridge with new one every 500  
hours or so.  
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.  
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.  
Cleaning Inside the Fuel Tank  
Vent any air  
If necessary, drain the fuel inside the fuel tank completely.  
Using a spray washer (Figure 58) wash out any deposits  
or debris that have accumulated inside the fuel tank.  
AIR REMOVAL  
If air enters the fuel injection system of a diesel engine,  
starting becomes impossible. After running out of fuel,  
or after disassembling the fuel system, bleed the system  
according to the following procedure. See the ISUZU  
Engine Manual for details.  
To restart after running out of fuel, turn the switch to the  
“ON” position for 15-30 seconds. Try again, if needed.  
Figure 58. Fuel Tank Cleaning  
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MAINTENANCE  
CHECK OIL LEVEL  
RADIATOR CLEANING  
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 28.  
The radiator (Figure 59) should be sprayed (cleaned) with  
a high pressure washer when excessive amounts of dirt  
and debris have accumulated on the cooling fins or tube.  
When using a high pressure washer, stand at least 5 feet  
(1.5 meters) away from the radiator to prevent damage to  
the fins and tube.  
Replacing Oil Filter  
Remove the old oil filter.  
Apply a film of oil to the gasket on the new oil filter.  
Install the new oil filter.  
After the oil cartridge has been replaced, the engine oil  
will drop slightly.Run the engine for a while and check for  
leaks before adding more oil if needed. Clean excessive  
oil from engine.  
FLUSHING OUT RADIATOR AND REPLACING  
COOLANT  
Figure 59. Radiator Cleaning  
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.  
GENERATOR STORAGE  
For long term storage of the generator the following is  
recommended:  
Check hoses for softening and kinks. Check clamps for  
signs of leakage.  
Drain the fuel tank completely.Treat with a fuel stabilizer  
if necessary.  
Tighten both cocks and replace the overflow tank.  
Completely drain the oil from the crankcase and refill if  
necessary with fresh oil.  
Replace with coolant as recommended by the engine  
manufacturer.  
Clean the entire generator, internal and external.  
Cover the generating set and store in a clean, dry place.  
Disconnect the battery.  
Close radiator cap tightly.  
Flush the radiator by running clean tap water through  
radiator until signs of rust and dirt are removed. DO  
NOT clean radiator core with any objects, such as a  
screwdriver.  
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.  
WARNING  
Allow engine to cool when flushing out  
radiator. Flushing the radiator while hot  
could cause serious burns from water or  
steam.  
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MAINTENANCE  
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.  
JACKETWATERHEATERANDINTERNALBATTERY  
CHARGER 120 VAC INPUT RECEPTACLES  
(OPTIONAL)  
This generator can be optionally equipped with two 120  
VAC, 20 amp input receptacles located on the output  
terminal panel.  
The purpose of these receptacles is to provide power via  
commercial power to the jacket water heater and internal  
battery charger.  
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.  
These receptacles will ONLY function when commercial  
power has been supplied to them (Figure 60). To apply  
commercial power to these receptacles, a power cord of  
adequate size will be required (See Table 6).  
NOTICE  
To ensure adequate starting capability, always have  
power applied to the generator's internal battery  
charger..  
Figure 60. Battery Charger & Jacket Water Heater Power Connections  
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TRAILER MAINTENANCE  
8. Tire Size — Indicates the diameter of the tire in  
inches (10,12,14, etc.), and the width in millimeters  
(175,185,205, etc.). The tire diameter must match the  
diameter of the tire rim.  
TRAILER MAINTENANCE  
This section is intended to provide the user with generic  
trailer service and maintenance information. The service  
and maintenance guidelines referenced in this section refer  
to a wide range of trailers.  
9. Tire Ply — The tire ply (layers) number is rated in  
letters; 2-ply,4-ply,6-ply, etc.  
Remember periodic inspection of the trailer will ensure safe  
towing of the generator and will prevent personal injury and  
damage to the equipment.  
10. Wheel Hub — The wheel hub is connected to the  
trailer’s axle.  
11. Tire Rim — Tires mounted on a tire rim. The tire rim  
must match the size of the tire.  
The definitions below describe some of the major  
components of a typical trailer that would be used with  
generator.  
12. Lug Nuts — Used to secure the wheel to the wheel  
hub. Always use a torque wrench to tighten down  
the lug nuts. See Table 18 and Figure 63 for lug nut  
tightening and sequence.  
1. Fuel Cell — Provides an adequate amount of fuel for  
the equipment in use. Fuel cells must be empty when  
transporting equipment.  
13. Axle — Indicates the maximum weight the axle can  
support in pounds, and the diameter of the axle  
expressed in inches. Please note that some trailers  
have a double axle.This will be shown as 2-6000 lbs.,  
meaning two axles with a total weight capacity of 6000  
pounds.  
2. Braking System — System employed in stopping  
the trailer.Typical braking systems are electric, surge,  
hydraulic, hydraulic-surge and air.  
3. GVWR — Gross Vehicle Weight Rating (GVWR) is  
the maximum number of pounds the trailer can carry,  
including the fuel cell (empty).  
14. Suspension — Protects the trailer chassis from shocks  
transmitted through the wheels. Types of suspension  
used are leaf, Q-flex, and air ride.  
4. Frame Length — Measurement is from the ball hitch  
to the rear bumper (reflector).  
5. Frame Width — Measurement is from fender to  
fender  
15. Electrical — Electrical connectors (looms) are provided  
with the trailer so the brake lights and turn signals can  
be connected to the towing vehicle.  
6. Jack Stand Trailer support device with maximum  
pound requirement from the tongue of the trailer.  
16. Application — Indicates which units can be employed  
on a particular trailer.  
7. Coupler — Type of hitch used on the trailer for  
towing.  
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TRAILER MAINTENANCE  
BRAKES  
Hydraulic Surge Brakes  
Trailer brakes should be inspected the first 200 miles of  
operation.This will allow the brake shoes and drums to seat  
properly.After the first 200 mile interval, inspect the brakes  
every 3,000 miles. If driving over rough terrain, inspect the  
brakes more frequently.  
Hydraulic surge brakes (Figure 61) should not require any  
special attention with the exception of routine maintenance  
such as shoe and lining replacement. Brake lines should  
be periodically checked for cracks, kinks, or blockage.  
Figure 61 displays the major hydraulic surge brake  
components that will require inspection and maintenance.  
Please inspect these components as required using steps  
1 through 8 and Table 15 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.  
Figure 61. Hydraulic Brake Components  
4. With a screwdriver or standard adjusting tool, rotate  
the star wheel of the adjuster assembly to expand the  
brake shoes.  
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 15. Hydraulic Brake Troubleshooting  
Symptom  
Possible Cause  
Solution  
No Brakes  
Brake line broken or kinked?  
Brake lining glazed?  
Repair or replace.  
Reburnish or replace.  
Correct weight.  
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?  
Replace components.  
Locking Brakes  
Noisy Brakes  
Brake drums out-of-round?  
System lubricated?  
Replace.  
Lubricate.  
Brake components correct?  
Replace and correct.  
Install new shoes and  
linings.  
Brake lining thickness incorrect or  
not adjusted correctly?  
Dragging Brakes  
Replace rubber parts  
fill with dot 4 fluid.  
Enough brake fluid or correct fluid?  
PAGE 42 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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TRAILER MAINTENANCE  
TIRES/WHEELS/LUG NUTS  
Suspension  
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.  
The leaf suspension springs and associated components  
(Figure 62) should be visually inspected every 6,000 miles  
for signs of excessive wear, elongation of bolt holes, and  
loosening of fasteners. Replace all damaged parts  
(suspension) immediately.Torqued suspension components  
as detailed in Table 17.  
CAUTION  
ALWAYS wear safety glasses when  
removing or installing force fitted parts.  
Failure to comply may result in serious  
injury.  
CAUTION  
DO NOT attempt to repair or modify a  
wheel. DO NOT install in inner tube to  
correct a leak through the rim. If the rim  
is cracked, the air pressure in the inner  
tube may cause pieces of the rim to explode (break off)  
with great force and cause serious eye or bodily injury.  
Figure 62. Major Suspension Components  
Tire Wear/Inflation  
Tire inflation pressure is the most important factor in tire  
life. Pressure should be checked cold before operation DO  
NOT bleed air from tires when they are hot!.Check inflation  
pressure weekly during use to insure the maximum tire life  
and tread wear.  
Table 17. Suspension Torque Requirements  
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 16 (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  
Shackle Bolt  
Spring Eye Bolt  
Table 16. Tire Wear Troubleshooting  
provided to retain nut-bolt assembly.  
Wear Pattern  
Cause  
Solution  
Shoulder Type  
Shackle Bolt  
Min-30 Max-50  
Adjust pressure to particular  
load per tire manufacturer.  
Center Wear Over inflation.  
Edge Wear Under inflation.  
Adjust pressure to particular  
load per tire manufacturer.  
Make sure load does not  
exceed axle rating.  
Align wheels.  
Loss of camber  
Side Wear  
or overloading.  
Toe Wear  
Cupping  
Incorrect toe-in.  
Out-of-balance.  
Align wheels.  
Check bearing adjustment  
and balance tires.  
Wheel lockup and Avoid sudden stops when  
tire skidding. possible and adjust brakes.  
Flat Spots  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 43  
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TRAILER MAINTENANCE  
Lug Nut Torque Requirements  
It is extremely important to apply and maintain proper wheel  
mounting torque on the trailer. Be sure to use only the  
fasteners matched to the cone angle of the wheel. Proper  
procedure for attachment of the wheels is as follows:  
1. Start all wheel lug nuts by hand.  
2. Torque all lug nuts in sequence (Figure 63). DO NOT  
torque the wheel lug nuts all the way down.Tighten each  
lug nut in 3 separate passes as defined by Table 18.  
3. After first road use, retorque all lug nuts in sequence.  
Check all wheel lug nuts periodically.  
Table 18. Tire Torque Requirements  
First Pass  
FT-LBS  
Second Pass  
FT-LBS  
Third Pass  
FT-LBS  
Wheel Size  
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 63. Wheel Lug Nuts  
Tightening Sequence  
NOTICE  
NEVER use an pneumatic air gun to tighten wheel  
lug nuts.  
PAGE 44 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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TRAILER WIRING DIAGRAM  
Figure 64. Trailer/Towing Vehicle Wiring Diagram  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 45  
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GENERATOR WIRING DIAGRAM  
Figure 65. Generator Wiring Diagram  
PAGE 46 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENGINE WIRING DIAGRAM  
Figure 66. Engine Wiring Diagram  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 47  
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CONTROLLER WIRING DIAGRAM  
Figure 67. Controller Wiring Diagram  
PAGE 48 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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TROUBLESHOOTING (GENERATOR)  
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a  
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our  
company’s business office or service plant.  
Table 19. Generator Troubleshooting  
Symptom  
Possible Problem  
AC Voltmeter defective?  
Is wiring connection loose?  
Is AVR defective?  
Solution  
Check output voltage using a voltmeter.  
Check wiring and repair.  
No Voltage Output  
Replace if necessary.  
Defective Rotating Rectifier? Check and replace.  
Defective Exciter Field?  
Is engine speed correct?  
Check for approximately 17.3 ohms across J & K on CN1  
Turn engine throttle lever to “High”.  
Low Voltage Output  
High Voltage Output  
Is wiring connections loose? Check wiring and repair.  
Defective AVR? Replace if necessary.  
Is wiring connections loose? Check wiring and repair.  
Defective AVR?  
Replace if necessary.  
Short Circuit in load?  
Over current?  
Check load and repair.  
Confirm load requirements and reduce.  
Check and replace.  
Circuit Breaker Tripped  
Defective circuit breaker?  
Over current Relay actuated? Confirm load requirement and replace.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 49  
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TROUBLESHOOTING (DIAGNOSTIC LAMP)  
The engine controller of this generator diagnoses problems  
that arise from the engine control system and the engine  
itself. Press the diagnostic button (Figure 68) on the  
diagnostic panel to determine if an engine malfunction has  
occurred.  
Figure 68. Diagnostic Panel  
METHOD OF OPERATION  
1. Normally, the diagnostic lamp will be dimly lit when  
the MPEC Control Switch is placed in the MANUAL  
position.  
2. If engine trouble occurs, the diagnostic lamp will be  
brightly lit as long as the control switch is left in the  
manual position.  
3. The diagnostic lamp will indicate that an engine  
malfunction has occurred.  
NOTICE  
For a complete understanding of error codes and  
troubleshooting procedures, refer to the enclosed  
engine instruction manual.  
NOTICE  
If the engine is cranked while the diagnostic switch is in  
the “ONposition, the engine will not be stopped even if  
the starter switch is turned to the “OFFposition.In such  
case, turn the diagnostic switch to the “OFF” position.  
PAGE 50 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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NOTES  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 51  
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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 theRemarks”  
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 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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SUGGESTED SPARE PARTS  
DCA125USI WHISPERWATT GENERATOR WITH  
ISUZU 4HK1X DIESEL ENGINE  
1 to 3 units  
QTY. P/N  
DESCRIPTION  
5............1132402322..........CARTRIDGE, OIL FILTER  
3............0602046684..........ELEMENT, AIR (OUTER)  
3............P777639 ...............ELEMENT, AIR (INNER)  
1............8980627130..........BELT, FAN  
3............M3310502603.......RADIATOR HOSE, UPPER  
3............M3310502703.......RADIATOR HOSE, LOWER  
3............8980714010..........FUEL FILTER, FEED PUMP  
3............8981430410..........FILTER FUEL, ELEMENT MAIN  
3............8980742880..........FILTER FUEL, ELEMENT PRE  
1............0602122272..........UNIT, OIL PRESSURE  
1............0602123260..........UNIT, WATER TEMPERATURE  
1............9095720140..........PACKING, WATER TEMPERATURE  
1............8121468300..........SENSOR, WATER TEMPERATURE  
1............8980274560..........SENSOR, OIL PRESSURE  
1............1096300850..........GASKET, OIL PRESSURE SENSOR  
1............8971256011..........SWITCH, OVERHEAT  
1............0601870440..........CIRCUIT BREAKER, 1P, 20 AMP  
1............0601870441..........CIRCUIT BREAKER 2P, 50 AMP  
1............0601820602..........AUTOMATIC VOLTAGE REGULATOR  
3............0601806671..........FUSE, 15 AMP  
1............0601806644..........FUSE, 30 AMP  
1............0601806640..........FUSE, 65 AMP  
2............LY2DUS12VDC ....RELAY  
NOTICE  
Part number on this Suggested Spare Parts list may  
supersede/replace the P/N shown in the text pages of  
this book.  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 53  
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GENERATOR ASSY.  
PAGE 54 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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GENERATOR ASSY.  
NO.  
1
PART NO.  
C0110001002  
PART NAME QTY. REMARKS  
ROTOR ASSY ..............................1 .......INCLUDES ITEMS W/#  
1-1#  
FIELD ASSY  
FAN  
COUPLING DISK  
1
1
8
1-2# 8131070013  
1-3# 8131611014  
1-4# 8131015003  
1-5# 0012112035  
1-6# 0042612000  
1-7# 8101026013  
1-8# 0601821349  
1-9# 0601822601  
1-10# 8001020004  
1-11# 8001020504  
1-12# 012210020  
1-13# 0040010000  
1-14# 0601000209  
1-15# 0071906312  
BALANCING PLATE.....................1 .......PURCHASE ITEM 1-14 AS A SET  
HEX HEAD BOLT  
WASHER, LOCK  
SET PLATE, RECTIFIER .............1 .......PURCHASE ITEM 1-14 AS A SET  
RECTIFIER  
SURGE ABSORBER  
WASHER, INSULATOR  
WASHER, INSULATOR  
HEX HEAD BOLT  
WASHER, LOCK  
BALANCING WEIGHT KIT  
BEARING  
10  
10  
2
1
1
1
4
4
1
1
2
3
4
5
6
7
8
9
C0130000503  
0845041804  
8131315202  
8101350013  
0012110060  
0042610000  
031110160  
0010112035  
0040012000  
031112230  
8131310104  
8131312204  
8131331003  
0105050616  
8101333003  
0010006030  
0040006000  
952404470  
STARTOR 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
12  
1
12  
12  
1
1
2
2
2
FIELD ASSY, EXCITER  
HEX HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
COVER,BEARING  
GASKET, BEARING  
COVER, END BRACKET  
HEX HEAD BOLT  
COVER, END BRACKET  
HEX HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
COUPLING RING  
HEX HEAD BOLT  
WASHER, LOCK  
HEX HEAD BOLT  
COUPLING ADAPTER  
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  
30  
30A  
M3163400503  
0010310075  
030210250  
012010030  
M3163600003  
012010030  
012010030  
8131332014  
0600815000  
0605000063  
0030016000  
0040016000  
NUT  
RUBBER SUSPENSION  
HEX NUT  
WASHER, LOCK  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 55  
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CONTROL BOX ASSY.  
PAGE 56 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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CONTROL BOX ASSY.  
NO.  
1
1-1  
1-2  
1-3  
2
2-1  
3
4
PART NO.  
PART NAME  
QTY.  
REMARKS  
M3213001802  
0330000210  
0330000280  
0330000340  
0601808827  
0342604120  
0021006080  
0601823863  
7538070  
CONTROL BOX  
EDGING  
EDGING  
1
2
1
2
1
6
4
2
EDGING  
CIRCUIT BREAKER, 3P 350A  
HEX SOCKET HEAD CAP SCREW  
MACHINE SCREW  
RELAY UNIT  
5
MACHINE SCREW .....................................4 ................REPLACES P/N 0027104016  
6
7
8
9
0601820602  
0027105016  
0601801124  
011206020  
0601820847  
0601820848  
7538070  
AUTOMATIC VOLTAGE REGULATOR  
MACHINE SCREW  
CURRENT TRANSFORMER  
HEX HEAD BOLT 6X20...............................6 ................REPLACES P/N 0027106020  
OVER CURRENT RELAY  
OVER CURRENT RELAY  
MACHINE SCREW .....................................2 ................REPLACES P/N 0027104016  
HEX NUT.....................................................2 ................REPLACES P/N 0207004000  
HOLDER, FUSE  
FUSE, 15A  
MACHINE SCREW  
TERMINAL  
MACHINE SCREW  
1
4
3
10  
11  
12  
12A  
13  
13A  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
28A  
28B  
29  
30  
31  
32  
35  
36  
37  
38  
39  
40  
40A  
40B  
41  
1
1
OEMAA8  
0601802218  
0601806671  
0027103016  
0601815153  
0027104020  
8121468300  
M3260500503  
0016906016  
8980710280  
M3260500604  
0016906016  
0601831205  
0601831330  
0016906016  
0601821370  
0027104030  
LY2DUS12VDC  
PTF08A  
1
3
2
1
2
SENSOR, INLET AIR TEMP........................1 ................REPLACES P/N 0603210240  
SET PANEL, ELECTRIC PARTS  
HEX HEAD BOLT  
CONTROLLER............................................1 ................REPLACES P/N 0602202686  
BRACKET  
1
4
1
4
1
1
4
HEX HEAD BOLT  
PUSH BUTTON SWITCH  
DIAGONASTIC SWITCH  
HEX HEAD BOLT  
RECTIFIER .................................................1 ................REPLACES P/N 0601823240  
MACHINE SCREW  
RELAY.........................................................2 ................REPLACES P/N 0601827656  
BASE...........................................................2 ................REPLACES P/N 0601823109  
CLIP ............................................................4 ................REPLACES P/N 0601824400  
MACHINE SCREW  
SENSOR, BAROMETRIC PRESSURE ......1 ................REPLACES P/N 0602130220  
MACHINE SCREW REPLACES P/N 0027104016  
RELAY, STARTER .......................................1 ................REPLACES P/N 0602201402  
MACHINE SCREW  
RELAY, GLOW PLUG..................................1 ................REPLACES P/N 0602202685  
1
PYCA1  
0027104020  
8972177780  
7538070  
4
2
5825530444  
0027105016  
8970119490  
0027105016  
M3213500704  
0016906016  
M3270100504  
M3550002504  
M3550002604  
M3213602704  
3
MACHINE SCREW  
CONTROL BOX COVER  
HEX HEAD BOLT  
SELECTOR SWITCH  
DECAL: SELECTOR SWITCH NUMBER 1  
DECAL: SELECTOR SWITCH NUMBER 1  
2
1
8
1
SWITCH BRACKET  
1
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 57  
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CONTROL BOX ASSY. ( CONTINUED)  
PAGE 58 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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CONTROL BOX ASSY. (CONTINUED)  
NO.  
42  
43  
43A  
44  
PART NO.  
PART NAME  
QTY.  
REMARKS  
M3213602804  
0027104035  
OEMAA8  
7538070  
OEMAA8  
SWITCH BRACKET  
MACHINE SCREW  
HEX NUT  
1
4
4
MACHINE SCREW .....................................4 ................REPLACES P/N 0027104016  
HEX NUT  
44A  
45  
4
4
1
1
1
10  
0016906016  
M3213602604  
46-1 0317700180  
HEX HEAD BOLT  
SWITCH COVER  
WEATHER STRIP  
SWITCH COVER  
HEX HEAD BOLT  
46  
47  
48  
49  
49A  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
59A  
60  
61  
61A  
62  
63  
64  
65  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
M3213602504  
0016906016  
011008020  
HEX HEAD BOLT.......................................10 ...............REPLACES P/N 0019208020  
TOOTHED WASHER  
CONTROL PANEL  
FREQUENCY METER, 45~65Hz 240V  
AC AMMETER, 0~200A/400A:5A  
CHANGE OVER SWITCH, AMMETER  
AC VOLTMETER, 0~600V  
CHANGE OVER SWITCH, VOLTMETER 1  
RHEOSTAT (VR), 2W 1K OHM  
KNOB ..........................................................1 ................REPLACES P/N 0601840121  
0040508000  
M3223001203  
0601807641  
0601808988  
0601801040  
0601806859  
0601801041  
0601840073  
0601840100  
0602202641  
0027104040  
OEMAA8  
1
1
1
1
1
1
1
CONTROLLER, ECU (CAN77)  
MACHINE SCREW  
HEX NUT  
1
2
2
82608  
SWITCH ......................................................1 ................REPLACES P/N 0601831340  
0602103092  
0601810245  
0602120095  
0602122093  
0602123090  
0602121081  
9826800370  
0601831330  
0601831395  
M1223100004  
M3223100004  
0027105010  
0027105010  
M9220100004  
0080200007  
0602122272  
M9200100004  
8943998582  
0602123260  
9095720140  
0602120465  
0601806644  
0601806640  
M3246703004  
M3357202002  
M3357201802  
ALARM LAMP  
BULB, DC 18V  
TACHOMETER  
OIL PRESSURE GAUGE  
WATER TEMPERATURE GAUGE  
CHARGING AMMETER  
3
3
1
1
1
1
PANEL LIGHT .............................................1 ................REPLACES P/N 0601810141  
SWITCH, PANEL LIGHT  
SWITCH, ENGINE SPEED  
STOPPER  
1
1
1
1
4
4
2
2
1
1
STOPPER  
MACHINE SCREW  
MACHINE SCREW  
SET SCREW  
SNAP RING  
UNIT, OIL PRESSURE  
ADAPTER  
ADAPTER....................................................1 ................REPLACES P/N 0602020220  
UNIT, WATER TEMPERATURE  
PACKING.....................................................1 ................REPLACES P/N 0602021109  
PICK UP, TACHOMETER  
FUSE, 30A  
FUSE, 65A  
1
1
1
1
1
1
1
WIRE HARNESS. GENERATOR  
WIRE HARNESS, ENGINE  
WIRE HARNESS, CONTROLLER  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 59  
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ENGINE AND RADIATOR ASSY.  
PAGE 60 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENGINE AND RADIATOR ASSY.  
NO.  
1
1A  
2
3
4
5
6
7
8
PART NO.  
PART NAME  
ENGINE, ISUZU 4HK1X  
FAN BELT....................................................1 ................REPLACES P/N 0602015253  
ENGINE FOOT  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0105091025  
WASHER, LOCK  
RUBBER SUSPENSION  
HEX NUT  
WASHER, LOCK  
RADIATOR  
CAP  
QTY.  
1
REMARKS  
M3923200144  
8980627130  
M3303200603  
0105091025  
0040010000  
060500060  
0030012000  
0040012000  
M3923200114  
0602011029  
M9200100904  
0150000016  
M3310202904  
011008020  
M3310202803  
M3493114104  
0016910025  
0016910025  
M3310202104  
011008020  
M3310502603  
M3310502703  
0605515148  
M3310600303  
0016906016  
M3310600204  
011206020  
M3310203003  
0016910025  
M1924200004  
0016910025  
0602046258  
0602046684  
P777639  
0602040650  
M3373200204  
011008020  
0602040596  
011008020  
020108060  
M3373101203  
M3373101103  
M3326100140  
0605515146  
2
8
2
2
2
1
1
1
1
2
8-1  
9
PLUG  
O-RING  
RADIATOR BRACKET  
10  
11  
12  
13  
13A  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
29A  
29B  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0019208020  
RADIATOR BRACKET  
ACOUSTIC SHEET  
HEX HEAD BOLT  
HEX HEAD BOLT  
RADIATOR BRACKET  
1
1
6
4
1
HEX HEAD BOLT........................................2 ................REPLACES P/N 0019208020  
RADIATOR HOSE, UPPER  
RADIATOR HOSE, LOWER  
HOSE BAND  
HOSE SUPPORT  
HEX HEAD BOLT  
HOSE BRACKET  
1
1
1
1
4
2
HEX HEAD BOLT........................................2 ................REPLACES P/N 0016906020  
FAN BRACKET  
HEX HEAD BOLT  
FAN MOTOR  
HEX HEAD BOLT  
AIR CLEANER  
ELEMENT, AIR CLEANER, OUTER  
ELEMENT, AIR CLEANER, INNER.............1 ................REPLACES P/N 0602046685  
INDICATOR, AIR CLEANER  
BRACKET AIR CLEANER  
HEX HEAD BOLT........................................2 ................REPLACES P/N 0019208020  
BAND, AIR CLEANER  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
HEX NUT.....................................................4 ................REPLACES P/N020108060  
HOSE, AIR CLEANER  
HOSE, AIR CLEANER  
BLOW BY PIPE  
1
4
2
8
1
1
1
1
2
1
1
1
1
HOSE BAND  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 61  
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ENGINE AND RADIATOR ASSY. (CONTINUED)  
PAGE 62 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENGINE AND RADIATOR ASSY. (CONTINUED)  
NO.  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
63A  
64  
64A  
64B  
65  
65A  
65B  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
78A  
79  
PART NO.  
PART NAME  
HOSE BAND  
AIR DUCT HOSE  
HOSE BAND  
BLOW BY HOSE  
HOSE BAND  
HOSE JOINT  
SEAL WASHER  
QTY.  
REMARKS  
0605515197  
M3373100903  
0605515197  
0191701050  
0605515149  
M9100000204  
0602021731  
7812014003B  
0802011104  
0150000018  
011206020  
0199102250  
0605515170  
0602022581  
0602022561  
0603306590  
0603300285  
0605511395  
0603306395  
0602021070  
0269200800  
M3323500004  
0016910025  
8973243861  
1132402322  
0010110120  
0040010000  
031110160  
3
1
1
1
2
1
1
DRAIN JOINT..............................................1 ................REPLACES P/N M2320300103  
PLUG...........................................................1 ................REPLACES P/N M9200200004  
O-RING  
HEX HEAD BOLT........................................2 ................REPLACES P/N 0016906020  
DRAIN HOSE  
HOSE BAND ...............................................2 ................REPLACES P/N 0605515106  
1
1
ADAPTER  
1
1
1
1
1
1
1
1
1
2
90 DEGREE ELBOW  
CONNECTOR  
LOCKNUT  
VALVE  
HOSE JOINT  
CAP  
DRAIN HOSE  
BRACKET, OIL FILTER  
HEX HEAD BOLT  
OIL FILTER..................................................1 ................REPLACES P/N 0602041007  
CARTRIDGE, OIL FILTER ..........................1 ................REPLACES P/N 0602041221  
HEX HEAD BOLT  
WASHER, LOCK  
2
2
WASHER, FLAT ..........................................2 ................REPLACES P/N 0041210000  
HEX HEAD BOLT  
WASHER, LOCK  
0010110150  
0040010000  
031110160  
2
2
WASHER, FLAT ..........................................2 ................REPLACES P/N 0041210000  
0602022530  
0602022930  
0379001250  
0605515198  
0802081003C  
0802010900  
M3316100303  
011008020  
0199102100  
0193600700  
0193601000  
0605515170  
M3923200124  
M3490202004  
0132004000  
ADAPTER  
HOSE JOINT  
HOSE  
4
4
2
4
HOSE BAND  
RESERVE TANK, 5L ...................................1 ................REPLACES P/N M9300000203  
CAP, RESERVE TANK.................................1 ................REPLACES P/N 0602010900  
BRACKET, RESERVE TANK  
HEX HEAD BOLT........................................3 ................REPLACES P/N 0019208020  
HOSE  
HOSE  
HOSE  
1
1
1
1
HOSE BAND ...............................................3 ................REPLACES P/N 0605515106  
INTERCOOLER  
ACOUSTIC SHEET  
PLUG, 3/8  
1
1
1
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 63  
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ENGINE AND RADIATOR ASSY. (CONTINUED)  
PAGE 64 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENGINE AND RADIATOR ASSY. (CONTINUED)  
NO.  
80  
80A  
81  
PART NO.  
PART NAME  
BRACKET, INTER COOLER  
ACOUSTIC SHEET  
QTY.  
1
2
REMARKS  
M3310202603  
M3493114504  
012210020  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0017110020  
82  
83  
84  
85  
86  
87  
88  
89  
0016906016  
M3310502803  
M3310502903  
0605515208  
0605515204  
0605515207  
M3310600404  
011206020  
HEX HEAD BOLT  
COOLER HOSE  
COOLER HOSE  
HOSE BAND  
HOSE BAND  
HOSE BAND  
12  
1
1
2
1
1
1
HOSE BRACKET  
HEX HEAD BOLT........................................1 ................REPLACES P/N 0016906020  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
103  
M3310303803  
M3310303903  
011206020  
M3310304104  
0016906016  
M3310304003  
011206020  
FAN SHROUD  
FAN SHROUD  
1
1
HEX HEAD BOLT........................................8 ................REPLACES P/N 0016906020  
BRACKET, FAN SHROUD  
HEX HEAD BOLT  
FAN GUARD  
HEX HEAD BOLT........................................6 ................REPLACES P/N 0016906020  
BLOWBY HOSE BRACKET  
HEX HEAD BOLT........................................1 ................REPLACES P/N 0019208020  
PACKING SENSOR WATER TEMP.  
SENSOR, WATER TEMPERATURE  
SENSOR, OIL PRESSURE  
GASKET, SENSOR OIL PRESSURE  
SWITCH, OVERHEAT  
1
8
1
M3326200204  
011008020  
1
9095720140  
8121468300  
8980274560  
1096300850  
8971256011  
1
1
1
1
1
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 65  
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OUTPUT TERMINAL ASSY.  
PAGE 66 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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OUTPUT TERMINAL ASSY.  
NO.  
1
2
3
4
5
6
7
8
PART NO.  
PART NAME  
TERMINAL BOARD  
OUTPUT TERMINAL BOLT  
TIE BOLT.....................................................5 ................REPLACES P/N M9220100404  
HEX NUT  
WASHER, LOCK  
WASHER, FLAT .........................................20 ...............REPLACES P/N 0041416000  
HEX HEAD BOLT........................................5 ................REPLACES P/N 0016908035  
TERMINAL COVER  
OUTPUT WINDOW  
HINGE  
QTY.  
1
5
REMARKS  
M3230700003  
M9220100304  
0801830804  
0039316000  
0040016000  
0401450160  
0012108035  
M3236100803  
M3236100404  
0605010040  
0027103010  
0207003000  
58413  
10  
15  
1
1
2
4
9
10  
11  
11A  
11B  
12  
12A  
13  
13A  
13B  
MACHINE SCREW  
HEX NUT.....................................................4 ................REPLACES P/N 0030003000  
WASHER, FLAT  
MACHINE SCREW  
4
4
REPLACES P/N 0041203000  
0027103010  
0207003000  
M9220100804  
0040006000  
952404470  
HEX NUT.....................................................4 ................REPLACES P/N 0030003000  
SET SCREW  
WASHER, LOCK  
WASHER, FLAT  
RETAINING RING  
HEX HEAD BOLT  
CABLE, OUTLET COVER  
SUPPORTER, CABLE OUTLET COVER 1  
HEX HEAD BOLT........................................6 ................REPLACES P/N 0016906020  
TERMINAL BLOCK  
MACHINE SCREW .....................................2 ................REPLACES P/N 0027104016  
BLIND PLUG  
MACHINE SCREW .....................................4 ................REPLACES P/N 0027104016  
2
2
2
2
4
1
13C 0080200005  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
0016906016  
M3236400004  
M3236300004  
011206020  
0601815194  
7538070  
0603306775  
7538070  
0601870440  
0601870441  
M1260700504  
1
2
CIRCUIT BREAKER, 1P 20A  
CIRCUIT BREAKER, 2P 50A  
BREAKER, FITTING COVER  
CUSHION RUBBER  
2
3
1
2
24-1 0222100100  
25  
26  
27  
28  
28A  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
011206020  
0601812597  
0601811034  
7538070  
HEX HEAD BOLT........................................2 ................REPLACES P/N 0016906020  
RECEPTACLE, GF530EM 125V 20Ax2......2 ................REPLACES P/N 0601812598  
RECEPTACLE, CS6369 250V 50A.............3 ................REPLACES P/N 0601812538  
MACHINE SCREW ....................................10 ...............REPLACES P/N 0027104016  
OEMAA8  
HEX NUT  
COVER  
10  
1
M3236400204  
0016906016  
M3236100213  
012212045  
031112230  
0805009804  
0030012000  
M4236100604  
M4236400304  
0016906016  
HEX HEAD BOLT  
TERMINAL COVER  
8
1
HEX HEAD BOLT........................................2 ................REPLACES P/N 012212045  
WASHER, FLAT  
STAY RUBBER............................................2 ................REPLACES P/N M9310200004  
2
HEX NUT  
COVER  
BRACKET  
HEX HEAC BOLT  
2
1
1
2
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 67  
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BATTERY ASSY.  
PAGE 68 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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BATTERY ASSY.  
NO.  
1
2
3
4
PART NO.  
PART NAME  
BATTERY  
QTY.  
REMARKS  
0602220198  
M9310500404  
M9103000504  
0602220921  
M3346901604  
M3346901504  
1
1
1
2
1
1
BATTERY SHEET  
BATTERY BAND  
BATTERY BOLT SET  
BATTERY CABLE  
BATTERY CABLE  
5
6
7
8
8A  
9
9A  
CABLE.........................................................1 ................MAKE LOCALLY  
HEX HEAD BOLT........................................1 ................REPLACES P/N 0017110030  
012010030  
0040510000  
011008020  
0040508000  
TOOTHED WASHER  
HEX HEAD BOLT........................................1 ................REPLACES P/N 0019208020  
TOOTHED WASHER  
1
1
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 69  
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MUFFLER ASSY.  
PAGE 70 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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MUFFLER ASSY.  
NO.  
1
2
3
4
PART NO.  
M3330101002  
012212030  
M3333001603  
141451840  
PART NAME  
MUFFLER  
QTY.  
1
REMARKS  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0017112030  
EXHAUST PIPE  
GASKET......................................................1 ................REPLACES P/N 0602320108  
1
5
6
7
8
9
10  
11  
M3333200304  
0039308000  
0017110050  
M3330401104  
M3330401003  
011008020  
GASKET  
HEX NUT  
HEX HEAD BOLT  
COVER  
BRACKET  
1
8
4
1
1
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
U-BOLT SET  
0602326061  
1
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 71  
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FUEL TANK ASSY.  
PAGE 72 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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FUEL TANK ASSY.  
NO.  
1
1-1  
1-2  
PART NO.  
PART NAME  
FUEL TANK  
FUEL TANK CAP  
FUEL SENDER UNIT  
GASKET  
QTY.  
REMARKS  
M3363001402  
0605505070  
0605501074  
1
1
1
1
1
1
2
4
4
4
8
1-2A 0605516090  
2
2-1  
3
4
5
6
7
8
M3363001504  
0605505070  
0191700260  
0605515134  
M3363200404  
M3363200904  
M9310500104  
011008020  
FUEL TANK  
FUEL TANK CAP  
CONNECT HOSE  
HOSE BAND  
TANK BAND  
TANK BAND  
SUPPORTER SHEET  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0019208020  
9
0207008000  
0222101000  
0191302500  
0605515109  
M3366700203  
011008020  
8980139861  
8981430410  
8980758551  
8980742880  
8973834270  
1096750951  
1096300860  
0017110040  
0010110080  
0040010000  
031110160  
8980682750  
8980714010  
011606025  
0191301790  
0191300800  
0191300230  
0191300850  
0191300750  
0605515109  
HEX NUT  
8
6
1
2
1
10  
11  
12  
13  
14  
15  
15A  
16  
16A  
17  
18  
19  
20  
21  
21A  
21B  
22  
22A  
23  
24  
25  
26  
27  
28  
29  
TANK SHEET  
VENT HOSE  
HOSE BAND  
FUEL FILTER BRACKET  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
FUEL FILTER (MAIN)..................................1 ................REPLACES P/N 0602042426  
ELEMENT, FUEL FILTER............................1 ................REPLACES P/N 8980088400  
FUEL FILTER (PRE.) ..................................1 ................REPLACES P/N 8980758550  
ELEMENT, FUEL FILTER............................1 ................REPLACES P/N 8980758540  
JOINT PIPE.................................................4 ................REPLACES P/N 0602042661  
JOINT BOLT................................................4 ................REPLACES P/N 0602042621  
PACKING.....................................................8 ................REPLACES P/N 0602042641  
HEX HEAD BOLT  
HEX HEAD BOLT  
WASHER, LOCK  
4
2
2
WASHER, FLAT ..........................................2 ................REPLACES P/N 0041210000  
FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023240  
FUEL FILTER ..............................................1 ................REPLACES P/N 0602042517  
HEX HEAD BOLT........................................2 ................REPLACES P/N 0016906025  
SUCTION HOSE  
SUCTION HOSE  
SUCTION HOSE  
SUCTION HOSE  
RETURN HOSE  
HOSE BAND  
1
1
1
1
1
10  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 73  
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ENCLOSURE ASSY. PART 1.  
PAGE 74 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENCLOSURE ASSY. PART1.  
NO.  
1
2
3
4
5
5A  
6
6A  
7
8
PART NO.  
PART NAME  
BASE  
ENVIROMENTAL TANK  
HEX HEAD BOLT  
PLUG, 1-1/2  
FRONT FRAME  
ACOUSTIC SHEET  
FRONT FRAME  
ACOUSTIC SHEET  
GROMMET  
QTY.  
1
1
12  
1
1
1
1
1
1
REMARKS  
M3413002502  
M3363300303  
0016910030  
0603306797  
M3423002802  
M3493114403  
M3423002902  
M3493114403  
0601851765  
011008020  
HEX HEAD BOLT.......................................27 ...............REPLACES P/N 0019208020  
FRONT FRAME  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0019208020  
9
M3423003003  
011008020  
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
22A  
23  
24  
24A  
25  
26  
27  
28  
29  
29A  
30  
30A  
30B  
0016910025  
M3310400403  
011206020  
M3310400304  
011206020  
M3423500204  
011008020  
M3423200704  
011206020  
M3310302704  
0016906016  
M3423300304  
M3493113704  
011008020  
M3423202603  
M3493111803  
M3423202403  
0019206016  
011008020  
HEX HEAD BOLT  
HOSE COVER  
6
1
HEX HEAD BOLT........................................7 ................REPLACES P/N 0016906020  
HOSE COVER  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0016906020  
BRACKET  
HEX HEAD BOLT........................................2 ................REPLACES P/N 0019208020  
DUCT COVER  
HEX HEAD BOLT.......................................14 ...............REPLACES P/N 0016906020  
SHROUD BRACKET  
HEX HEAD BOLT  
DISCHARGE GUIDE  
ACOUSTIC SHEET  
1
1
2
1
6
1
1
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
COVER FRONT FRAME  
ACOUSTIC SHEET  
FRONT LOUVER  
1
1
1
6
HEX HEAD BOLT  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
CENTER FRAME  
ACOUSTIC SHEET  
HEX HEAD BOLT  
HEX NUT  
011008020  
M3433001402  
M3493201304  
0010114040  
515455840  
1
1
4
4
REPLACES P/N 0030014000  
030214350  
WASHER, LOCK.........................................4 ................REPLACES P/N 0040014000  
30C 0041220000  
WASHER, FLAT  
HEX HEAD BOLT  
HEX NUT  
8
4
4
31  
0010120050  
0030020000  
030220510  
31A  
31B  
WASHER, LOCK.........................................4 ................REPLACES P/N 0040020000  
31C 0041220000  
WASHER, FLAT  
ROOF PANEL  
ACOUSTIC SHEET  
8
1
1
32  
32A  
M3463101503  
M3493509204  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 75  
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ENCLOSURE ASSY. PART 1 (CONTINUED)  
PAGE 76 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENCLOSURE ASSY. PART 1 (CONTINUED)  
NO.  
33  
33A  
34  
35  
36  
36A  
37  
PART NO.  
PART NAME  
QTY.  
1
1
2
12  
1
REMARKS  
M3463202202  
M3493509303  
M3463201104  
0016906016  
M3463202303  
M3493506004  
011008020  
ROOF PANEL  
ACOUSTIC SHEET  
BACK PLATE  
HEX HEAD BOLT  
DUCT  
ACOUSTIC SHEET  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0019208020  
1
38  
38A  
39  
40  
41  
42  
43  
M3423202704  
M3493108004  
011008020  
0017110025  
M3310600004  
011008020  
OVER COVER, FRONT FRAME  
ACOUSTIC SHEET  
HEX HEAD BOLT.......................................51 ...............REPLACES P/N 0019208020  
HEX HEAD BOLT........................................8 ................REPLACES P/N 0019210025  
COVER, RADIATOR CAP  
HEX HEAD BOLT........................................4 ................REPLACES P/N 0019208020  
HEX HEAD BOLT........................................1 ................REPLACES P/N 0019208020  
1
1
1
011008020  
43A  
44  
45  
46  
0040508000  
0605503062  
M1414800104  
011008020  
TOOTHED WASHER  
FUEL LEAK DETECTED SWITCH  
BRACKET  
1
1
1
HEX HEAD BOLT........................................2 ................REPLACES P/N 0019208020  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 77  
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ENCLOSURE ASSY. PART 2.  
PAGE 78 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENCLOSURE ASSY. PART 2.  
NO.  
1
1A  
2
PART NO.  
PART NAME  
REAR FRAME  
ACOUSTIC SHEET  
DUCT  
QTY.  
REMARKS  
M3443001902  
M3493308603  
M3443002004  
011008020  
1
1
2
3
HEX HEAD BOLT...........................................6 .................REPLACES P/N 0019208020  
4
M3443400103  
M3493308904  
0314501550  
0330000250  
0330000325  
011008020  
PANEL, REAR FRAME  
ACOUSTIC SHEET  
RUBBER SEAL  
EDGING  
1
1
1
1
1
4A  
4-1  
4-2  
4-3  
5
EDGING  
HEX HEAD BOLT...........................................6 .................REPLACES P/N 0019208020  
6
6A  
7
7A  
8
9
M3443002103  
M3493308804  
M3443002203  
M3443008804  
011008020  
DUCT  
1
1
1
1
ACOUSTIC SHEET  
DUCT  
ACOUSTIC SHEET  
HEX HEAD BOLT...........................................6 .................REPLACES P/N 0019208020  
HEX HEAD BOLT...........................................6 .................REPLACES P/N 0019208020  
011008020  
10  
11  
11A  
12  
13  
14  
15  
16  
16A  
17  
18  
18A  
19  
20  
21  
22  
22A  
23  
23A  
23B  
24  
25  
25A  
26  
26A  
27  
27A  
28  
28A  
0016910025  
M3443301803  
M3493308704  
011008020  
HEX HEAD BOLT  
COVER, REAR FRAME  
ACOUSTIC SHEET  
HEX HEAD BOLT...........................................4 .................REPLACES P/N 0019208020  
HEX HEAD BOLT...........................................4 .................REPLACES P/N 0019208020  
DOOR, REAR FRAME  
WINDOW PLATE  
HEX NUT  
4
1
2
011008020  
M3443200803  
M3443600304  
0207306000  
952404470  
B9114000002  
0021806016  
020106050  
M9110100204  
M9116100004  
011008020  
M3453201702  
M3493426704  
0019104065  
0042308000  
0042408000  
0016910025  
M3453005303  
M3493426504  
M3453005403  
M3493426504  
M3453002703  
M3493417204  
M3453005503  
M3493426604  
1
1
8
8
WASHER, FLAT  
DOOR HANDLE ASSY ..................................1 .................REPLACES P/N M9113000002  
MACHINE SCREW  
HEX NUT .......................................................4 .................REPLACES P/N 0030006000  
HINGE  
WASHER  
4
2
2
HEX HEAD BOLT...........................................3 .................REPLACES P/N 0019208020  
SPLASHER PANEL  
ACOUSTIC SHEET  
HEX HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX HEAD BOLT  
SIDE DOOR  
ACOUSTIC SHEET  
SIDE DOOR  
ACOUSTIC SHEET  
SIDE DOOR  
1
1
4
4
4
2
1
1
1
1
1
1
1
1
ACOUSTIC SHEET  
SIDE DOOR  
ACOUSTIC SHEET  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 79  
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ENCLOSURE ASSY. PART 2 (CONTINUED)  
PAGE 80 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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ENCLOSURE ASSY. PART 2 (CONTINUED)  
NO.  
29  
29A  
30  
30A  
31  
32  
33  
34  
35  
36  
37  
38  
39  
PART NO.  
PART NAME  
DOOR HANDLE ASSY ...............................4 ................REPLACES P/N M9113000002  
QTY.  
REMARKS  
B9114000002  
C9312500004  
0021806016  
020106050  
0845046904  
0845047004  
M9116100004  
011008020  
0601850097  
0027208025  
M9310000004  
0600800320  
0021806016  
SEAL RUBBER  
MACHINE SCREW  
4
16  
HEX NUT....................................................16 ...............REPLACES P/N 0030006000  
HINGE.........................................................6 ................REPLACES P/N M9110100804  
HINGE.........................................................5 ................REPLACES P/N M9110100904  
WASHER  
11  
HEX HEAD BOLT.......................................26 ...............REPLACES P/N 0019208020  
STOPPER  
MACHINE SCREW  
CAP  
MANUAL PAK  
MACHINE SCREW  
8
8
13  
1
4
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 81  
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RUBBER SEALS ASSY.  
PAGE 82 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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RUBBER SEALS ASSY.  
NO.  
1
2
3
4
5
6
7
8
PART NO.  
PART NAME  
QTY.  
1
1
3
1
1
4
3
4
3
1
4
1
1
2
1
1
1
2
1
1
1
1
2
2
REMARKS  
0229200870  
0229201130  
0229201240  
0228901070  
0314502700  
0229200125  
0228901165  
0228900925  
0228901105  
0228900565  
0228900945  
0228900505  
0229201090  
0229201335  
0228901335  
0228900655  
0229201090  
0228100630  
0229401080  
0228800565  
0228801080  
0228800545  
0228100370  
0228100640  
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  
RUBBER SEAL  
RUBBER SEAL  
RUBBER SEAL  
RUBBER SEAL  
RUBBER SEAL  
RUBBER SEAL  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 83  
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NAMEPLATE AND DECALS ASSY.  
PAGE 84 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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NAMEPLATE AND DECALS ASSY.  
NO.  
1-1  
1-2  
1-3  
PART NO.  
PART NAME  
QTY.  
REMARKS  
M3550003003  
M9520100304  
M9520100603  
DECAL : OPERATING PROCEDURES.....................1 ........... M35000300A  
DECAL : SAFETY INSTRUCTIONS..........................1 ........... M92010030  
DECAL : CAUTION....................................................2 ........... M92010060  
CONTROL BOX GROUP  
2-1  
2-2  
2-3  
2-4  
2-5  
2-6  
2-7  
2-8  
2-9  
M3550003503  
M3550003603  
M9520000104  
M9520000204  
M9520000804  
M9520000904  
M9520001104  
M9520100004  
M9520100204  
DECAL : CONTROL PANEL......................................1 ........... M35000350  
DCEAL : OPERATING PANEL...................................1 ........... M35000360  
PLATE : AMMETER CHANGE- OVER SWITCH.......1 ........... M92000010  
PLATE : VOLTMETER CHANGE- OVER SWITCH....1 ........... M92000020  
DECAL : AC...............................................................1 ........... M92000080  
DECAL : DIAGNOSTIC SWITCH ..............................1 ........... M92000090  
DECAL : DIAGNOSTIC BUTTON..............................1 ........... M92000110  
DECAL : WARNING ELECTRIC SHOCK HAZZARD 1 ........... M92010000  
DECAL : CAUTION....................................................1 ........... M92010020A  
DECAL : OVER CURRENT RELAY...........................1 ........... M92020040  
2-10 M9520200404  
ENGINE & RADIATOR GROUP  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
3-7  
M9500000004  
M9500100004  
M9500100304  
M9503000004  
M9503000103  
M9503100004  
M9510100004  
DECAL : OIL DRAIN PLUG.......................................1 ........... M90000000  
DECAL : WATER .......................................................1 ........... M90010000  
DECAL : INTER-COOLER DRAIN ............................1 ........... M90010030  
DECAL : WARNING MOVING PARTS.......................2 ........... M90300000  
DECAL : WATER - OIL CHECK................................1 ........... M90300010  
DECAL : WARNING HOT COOLANT........................1 ........... M90310000  
DECAL : CAUTION HOT PARTS...............................1 ........... M91010000  
OUTPUT TERMINAL GROUP  
4-1  
4-2  
4-3  
4-4  
4-5  
4-6  
4-7  
4-8  
4-9  
M1550000204  
M1550002203  
M3550000004  
M9520000004  
M9520000504  
M9520100004  
M9520100404  
M9520100503  
M9520200003  
DECAL : NOTE..........................................................1 ........... M15000020  
DECAL : RECEPTACLE & CIRCUIT BREAKER.......1 ........... M15000220  
DECAL : NOTE..........................................................1 ........... M35000000  
DECAL : GROUND....................................................1 ........... M92000000  
DECAL : START CONTACT.......................................1 ........... M92000050  
DECAL : WARNING ELECTRIC SHOCK HAZZARD 1 ........... M92010000  
DECAL : DANGER HIGH VOLTAGE..........................1 ........... M92010040  
DECAL : WARNING...................................................1 ........... M92010050  
DECAL : OUTPUT TERMINAL..................................1 ........... M92020000  
BATTERY GROUP  
5-1  
5-2  
5-3  
M9500300004  
M9500300104  
M9510100403  
DECAL : - ..................................................................1 ........... M90030000  
DECAL : +..................................................................1 ........... M90030010  
DECAL : CAUTION....................................................1 ........... M91010040  
MUFFLER GROUP  
DECAL : WARNING ENGINE EXHAUST..................1 ........... M90320000  
6-1  
M9503200004  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 85  
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NAMEPLATE AND DECALS ASSY. (CONTINUED)  
PAGE 86 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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NAMEPLATE AND DECALS ASSY. (CONTINUED)  
NO.  
PART NO.  
PART NAME  
FUEL TANK GROUP  
QTY.  
REMARKS  
7-1  
7-2  
M9500500004  
M9510000004  
DECAL : DIESEL FUEL.............................................1 ........... M90050000  
DECAL : FUEL DRAIN PLUG ...................................1 ........... M91000000  
ENCLOSURE GROUP  
8-1  
8-2  
8-3  
8-4  
8-5  
8-6  
8-7  
8-8  
8-9  
M9512200004  
M9510200304  
M3560102004  
M3560102103  
M3560102204  
M3560102303  
M3560102403  
M3560102504  
M9510100304  
DECAL : MQ..............................................................1 ........... M91220000  
DECAL : MQ POWER ...............................................2  
STRIPE .....................................................................2  
STRIPE : WHISPERWATT.........................................2  
STRIPE .....................................................................2  
STRIPE : 125.............................................................1  
STRIPE : 125.............................................................1  
STRIPE .....................................................................2  
DECAL : ENVIRONMENTAL WARNING...................1 ........... M91010030  
PLATE : MQ POWER ................................................1  
MACHINE SCREW....................................................4  
DECAL : CAUTION....................................................1 ........... M35000220  
DECAL : DANGER EXHAUST GAS..........................1 ........... M90320010  
DECAL : DOCUMENT BOX LOCATED.....................1 ........... M91000010  
8-10 0600500092  
8-10A 0021106016  
8-11 M3550002204  
8-12 M9503200104  
8-13 M9510000104  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 87  
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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 88 — DCA125USI 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11)  
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NOTES  
DCA125USI 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (03/25/11) — PAGE 89  
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OPERATION AND PARTS MANUAL  
HERE’S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL  
NUMBER ON-HAND WHEN CALLING  
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.  
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