Multiquip Portable Generator DCA 100SSJU User Manual

PARTS AND OPERATION MANUAL  
PARTS AND OPERATION MANUAL  
Table of Contents  
MQ POWER  
DCA-100SSJU  
TM  
WHISPERWATT  
GENERATOR  
(Standard)  
PARTS LIST NO. M3870300174  
S/N UP TO 7400295-100SSJU  
S/N FROM 7400296~100SSJU2  
Revision #2 (05/03/01)  
MULTIQUIPINC.  
18910 WILMINGTON AVE.  
PARTS DEPARTMENT:  
800-427-1244  
CARSON, CALIFORNIA 90746 FAX: 800-672-7877  
310-537-3700  
800-421-1244  
SERVICE DEPARTMENT:  
800-835-2551  
FAX:310-537-3927  
FAX:310-638-8046  
E-mail:mq@multiquip.com www:multiquip.com  
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Table of Contents  
PAGE 2 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)  
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Table of Contents  
HERE'S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL NUMBER  
ON-HANDWHEN CALLING  
PARTS DEPARTMENT  
800/427-1244 or 310/537-3700  
FAX: 800/672-7877 or 310/637-3284  
SERVICE DEPARTMENT  
800/835-2551 or 310/537-3700  
FAX: 310/638-8046  
WARRANTY DEPARTMENT  
800/835-2551 or 310/537-3700  
FAX: 310/638-8046  
MAIN  
800/421-1244 or 310/537-3700  
FAX: 310/537-3927  
DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 3  
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TABLE OF CONTENTS  
Here's How To Get Help ............................................... 3  
Table Of Contents ........................................................ 4  
Parts Ordering Procedures .......................................... 5  
Rules for Safe Operation .......................................... 6-9  
Towing Rules for Safe Operation ............................... 10  
Trailer Safety Guidelines............................................ 11  
Trailer Specifications ............................................ 12-13  
Trailer Braking System ......................................... 14-15  
Trailer Tires & Suspension .................................... 16-17  
TrailerWiring Diagram ................................................ 18  
Trailer Troubleshooting (Electric Brakes) .................... 19  
TrailerTroubleshooting (Hydraulic Brakes) ................. 20  
Operation Decals .................................................. 21-22  
DCA 100SSJU Specifications ................................... 23  
EngineTroubleshooting ......................................... 56-57  
Generator/EngineTroubleshooting ............................. 58  
MPECTroubleshooting .............................................. 59  
Explanation of Codes in Remarks Column ................ 60  
Suggested Spare Parts ............................................. 61  
Generator Assembly............................................. 62-63  
Control Box Assembly.......................................... 64-67  
Engine & Radiator Assembly................................. 68-71  
Engine Operating Panel Assembly ........................ 72-73  
Output Terminal Assembly..................................... 74-75  
Battery Assembly .................................................. 76-77  
Muffler Assembly .................................................. 78-79  
Fuel Tank Assembly .............................................. 80-81  
Enclosure Assembly ............................................. 82-85  
Rubber Seal Assembly .......................................... 86-87  
Name Plate And Decals ........................................ 88-89  
MQ POWER DCA-100SSJU  
AC GENERATOR  
Terms and Condition of Sale — Parts ....................... 90  
General Information ................................................... 24  
Major Components .................................................... 25  
Dimensions................................................................ 26  
Control Panel Descriptions ................................... 28-29  
Engine Operating Panel w/key............................. 30-31  
Engine Operating Panel w/MPEC ......................... 32-33  
OutputTerminal Panel Overview ........................... 34-41  
Installation ............................................................ 42-43  
Pre Setup ............................................................. 44-47  
Load Application ........................................................ 48  
Generator Start-up Procedure (Manual) ................ 49-51  
Generator Start-up Procedure (Auto) ......................... 52  
Generator Shutdown Procedure ................................. 53  
Maintenance ......................................................... 54-55  
NOTE  
Specification and part number  
are subject to change without  
notice.  
PAGE 4 DCA-100SSJU PARTS AND OPERATION MANUAL (STD) REV. #2 (05/03/01)  
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Table of Contents  
PARTS ORDERING PROCEDURES  
Dealer account number  
Dealer name and address  
Shipping address (if different than billing address)  
Return fax number  
Applicable model number  
Quantity, part number and description of each part  
Specify preferred method of shipment:  
UPS Ground  
UPS Second Day or Third Day*  
UPS Next Day*  
Federal Express Priority One (please provide us with your Federal  
Express account number)*  
Airborne Express*  
Truck or parcel post  
*Normally shipped the same day the order is received, if prior to 2PM west coast time.  
Earn Extra Discounts when  
you order by FAX!  
All parts orders which include complete part numbers  
and are received by fax qualify for the following extra  
discounts:  
Number of  
line items ordered  
Additional Discount  
1-9 items  
3%  
10+ items**  
5%  
only  
s
der  
ed or  
x
a
f
For  
Get special freight allowances  
when you order 10 or more  
line items via FAX!**  
Now! Direct TOLL-FREE access  
to our Parts Department!  
UPS Ground Service at no charge for freight  
PS Third Day Service at one-half of actual freight cost  
Toll-free nationwide:  
800-421-1244  
No other allowances on freight shipped by any other carrier.  
**Common nuts, bolts and washers (all items under $1.00 list price)  
do not count towards the 10+ line items.  
Toll-free FAX:  
*DISCOUNTS ARE SUBJECT TO CHANGE*  
800/6-PARTS-7 • 800-672-7877  
Fax order discount and UPS special programs revised June 1, 1995  
DCA-100SSJU PARTS AND OPERATION MANUAL (STD)REV. #2 (05/03/01) PAGE 5  
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Table of Contents  
RULES FOR SAFE OPERATION  
CAUTION:  
NEVER touch the hot exhaust  
manifold, muffler or cylinder. Allow  
these parts to cool before servicing  
engine or generator.  
Failure to follow instructions in this manual  
may lead to serious injury or even death!  
This equipment is to be operated by trained  
and qualified personnel only!This equipment  
is for industrial use only.  
The following safety guidelines should always be used when  
operating the DCA-100SSJU portable generator:  
High Temperatures Allow the engine to cool before  
adding fuel or performing service and maintenance  
functions. Contact with hot components can cause serious  
burns.  
GENERAL SAFETY  
DONOToperateorservicethisequipmentbefore  
reading this entire manual.  
The engine of this generator requires an adequate free  
flow of cooling air. Never operate the generator in any  
enclosed or narrow area where free flow of the air is  
restricted. If the air flow  
This equipment should not be operated by  
persons under 18 years of age.  
is restricted it will cause  
serious damage to the  
generator or engine and  
may cause injury to  
people. The generator  
NEVER operate this equipment without proper  
protective clothing, shatterproof glasses, steel-  
toed boots and other protective devices  
required by the job.  
engine gives off DEADLY  
carbon monoxide gas.  
NEVER operate this equipment when not feeling  
well due to fatigue, illness or taking medicine.  
CAUTION  
:
NEVER operate this equipment under the  
Always refuel in a well-ventilated area,  
away from sparks and open flames.  
influence or drugs or alcohol.  
NEVER use accessories or attachments, which are not  
recommended by MQ Power for this equipment. Damage  
to the equipment and/or injury to user may result.  
Always use extreme caution when  
working with flammable liquids. When  
refueling, stop the engine and allow it  
to cool. DO NOT smoke around or near  
the machine. Fire or explosion could  
result from fuel vapors, or if fuel is spilled  
on a hot engine.  
Manufacturer does not assume responsibility for any  
accident due to equipment modifications.  
Whenever necessary, replace nameplate, operation and  
safety decals when they become difficult read.  
Always check the machine for loosened threads or bolts  
NEVER operate the generator in an  
before starting.  
explosive atmosphere or near combustible  
materials. An explosion or fire could result  
causing severe bodily harm or even  
death.  
Topping-off to filler port is  
dangerous, as it tends to spill fuel.  
PAGE 6 DCA-100SSJU PARTS AND OPERATION MANUAL (STD) REV. #2 (05/03/01)  
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RULES FOR SAFE OPERATION  
CAUTION  
:
CAUTION  
:
DO NOT touch or open any of the below  
mentioned components while the  
generator is running. Always allow  
sufficient time for the engine and generator  
to cool before performing maintenance.  
NEVER touch output terminals during operation. This is  
Radiator  
extremely dangerous. Always stop the machine when  
1. Radiator Cap - Removing the radiator cap while the  
engine is hot will result in high pressurized, boiling water  
to gush out of the radiator, causing severe scalding to  
any persons in the general area of the generator.  
contact with the output terminals is required.  
CAUTION  
:
Backfeed to a utility system can cause electrocution  
and.or property damage. Do not connect to any  
building's electrical system except through an approved  
device or after building main switch is opened.  
2. Coolant Drain Plug - Removing the coolant drain plug  
while the engine is hot will result in hot coolant to gush  
out of the coolant drain plug, therefore causing severe  
scalding to any persons in the general area of the  
generator.  
CAUTION  
:
3. Engine Oil Drain Plug - Removing the engine oil drain  
plug while the engine is hot will result in hot oil to gush  
out of the oil drain plug, therefore causing severe  
scalding to any persons in the general area of the  
generator.  
Never use damaged or worn cables when connecting  
power tools or equipment to the generator. Make sure  
power connecting cables are securely connected to the  
generator’s output terminals, insufficient tightening of the  
terminal connections may cause damage to the generator  
and electrical shock.  
DCA-100SSJU — PARTS AND OPERATION MANUAL(STD)— REV. #2 (05/03/01) — PAGE 7  
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RULES FOR SAFE OPERATION  
Battery  
NEVER Run engine without air filter. Severe engine  
damage may occur.  
CAUTION  
:
Always service air cleaner frequently to prevent carburetor  
Never over fill the battery with water above  
the upper limit.  
malfunction.  
Always disconnect the battery before performing service  
on the generator.  
Always be sure the operator is familiar with proper safety  
precaution s and operations techniques before using  
generator.  
The battery contains acids that can cause injury to the eyes  
and skin.To avoid eye irritation, always wear safety glasses.  
Use well insulated gloves when picking up the battery. Use  
the following guidelines when handling the battery:  
Always store equipment properly when not in use.  
Equipment should be stored in a clean, dry location out of  
the reach of children.  
DO NOT leave the generator running in the manual mode  
unattended.  
DO NOT allow unauthorized people to operate this  
equipment.  
1. DO NOT drop the battery. There is the possibility of risk  
Always read, understand, and follow procedures in  
that the battery may explode.  
Operators Manual before attempting to operate equipment.  
2. DO NOT expose the battery to open flames, sparks,  
cigarettes etc. The battery contains combustible gases  
and liquids. If these gases and liquids come in contact  
with a flame or spark, an explosion could occur.  
Refer to the John Deere Engine Owner's Manual for  
engine technical questions or information.  
Loading and Unloading (Crane)  
Before lifting, make sure the generator's lifting hook is  
secure and that there is no apparent damage to the  
generator itself (loose screws, nuts and bolts). If any  
part is loose or damaged, please take corrective action  
before lifting.  
3. Always keep the battery charged. If the battery is not  
charged a buildup of combustible gas will occur.  
4. Always keep battery charging and booster cables in good  
working condition. Repair or replace all worn cables.  
5. Always recharge the battery in an open air environment,  
to avoid risk of a dangerous concentration of combustible  
gases.  
Always drain fuel prior to lifting.  
Always make sure crane or lifting device has been  
properly secured to the hook of guard frame on generator.  
6. In case the battery liquid (dilute sulfuric acid) comes in  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
NEVER lift the machine while the engine is running.  
Use adequate lifting cable (wire or rope) of sufficient  
strength.  
7. In case the battery liquid (dilute sulfuric acid) comes in  
contact with your eyes, rinse eyes immediately with  
plenty of water, then contact the nearest doctor or hospital,  
and seek medical attention.  
When lifting the generator, always use the balanced  
center-point suspension hook and lift straight upwards.  
NEVER allow any person or animal to stand underneath  
the machine while lifting.  
When loading the generator on a truck, be sure to use  
the front and back frame bars as a means to secure the  
generator during transport.  
PAGE 8 DCA-100SSJU PARTS AND OPERATION MANUAL (STD) REV. #2 (05/03/01)  
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RULES FOR SAFE OPERATION  
Transporting  
Maintenance Safety  
Always shutdown engine before transporting.  
NEVER lubricate components or attempt service on a  
running machine.  
Tighten fuel tank cap securely.  
Always allow the machine a proper amount of time to  
cool before servicing.  
Drain fuel when transporting generator over long distances  
or bad roads.  
Keep the machinery in proper running condition.  
Always tie-down the generator during transportation by  
securing the generator.  
Fix damage to the machine immediately and always  
replace broken parts.  
If generator is mounted on a trailer, make sure trailer  
complies with all local and state safety transportation  
laws. See page 10 for basic towing procedures.  
Dispose of hazardous waste properly. Examples of  
potentially hazardous waste are used motor oil, coolant,  
fuel, and fuel filters.  
Emergencies  
DO NOT use plastic containers to dispose of hazardous  
waste.  
Always know the location of the nearest fire extinguisher  
and first aid kit. Know the location of the nearest telephone.  
Also know the phone numbers of the nearest ambulance,  
doctor and fire department.  
DO NOT pour waste, oil, coolant or fuel directly onto the  
ground, down a drain or into any water source.  
DCA-100SSJU PARTS AND OPERATION MANUAL (STD)REV. #2 (05/03/01) PAGE 9  
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DCA-100SSJU TOWING RULES FOR SAFE OPERATION  
Towing Safety Precautions  
ALWAYS attach trailers safety chain to bumper of towing  
vehicle.  
CAUTION :  
ALWAYS make sure the vehicle and trailer directional,  
backup, brake, and trailer lights are connected and  
working properly.  
Check with your county or state safety  
towing regulations department before towing  
your generator.  
The maximum speed for highway towing is 45 MPH  
unless posted otherwise. Recommended off-road towing  
is not to exceed 10 MPH or less depending on type of  
terrain.  
To reduce the possibility of an accident  
while transporting the generator on public roads, always  
make sure the trailer (Figure 1) that supports the generator  
and the towing vehicle are in good operating condition and  
both units are mechanically sound.  
Place chocked blocks underneath wheel to prevent  
rolling, while parked.  
Place support blocks underneath the trailers bumper to  
prevent tipping, while parked.  
The following list of suggestions should be used when towing  
your generator:  
Use the trailers hand winch to adjust the height of the  
trailer, then insert locking pin to lock wheel stand in place,  
while parked.  
Make sure the hitch and coupling of the towing vehicle  
are rated equal to, or greater than the trailer "gross vehicle  
weight rating" (GVWR).  
Avoid sudden stops and starts. This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve gas milage.  
ALWAYS inspect the hitch and coupling for wear.NEVER  
tow a trailer with defective hitches, couplings, chains  
etc.  
Avoid sharp turns to prevent rolling.  
Check the tire air pressure on both towing vehicle and  
trailer. Also check the tire tread wear on both vehicles.  
Remove wheel stand when transporting.  
DO NOT transport generator with fuel in tank.  
ALWAYS make sure the trailer is equipped with a "Safety  
Chain".  
Figure 1. Generator with Trailer  
PAGE 10 DCA-100SSJU PARTS AND OPERATION MANUAL (STD) REV. #2