PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATTTM SERIES
MODEL DCA-100SSVU
60 Hz GENERATOR
PARTS LIST NO. M3870300704F
Revision #0 (11/05/07)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
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PAGE 2 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
© COPYRIGHT 2007, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, 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 thier 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 are
based on the DCA-100SSVU WHISPERWATT AC Generator.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.
To find the latest revision of this
publication, visit our website at:
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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 3
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TABLE OF CONTENTS
MQ POWER DCA-100SSVU
COMPONENT DRAWINGS
WHISPERWATTTM GENERATOR
Generator Assembly.................................................. 54-55
Engine Operating Panel Assembly ............................ 56-57
Control Box Assembly (S/N 7800129 and Below) ..... 58-61
Control Box Assembly (S/N 7800130 and Above) ..... 62-65
Engine and Radiator Assembly ................................. 66-67
Output Terminal Assembly......................................... 68-69
Actuator Assembly .................................................... 70-71
Battery Assembly ...................................................... 72-73
Muffler Assembly ...................................................... 74-75
Fuel Tank Assembly .................................................. 76-77
Enclosure Assembly ................................................. 78-81
Rubber Seals Assembly ............................................ 82-83
Nameplate and Decals .............................................. 84-87
California Proposition 65 Warning .....................................2
Here's How To Get Help ....................................................3
Table Of Contents .............................................................4
Parts Ordering Procedures ...............................................5
Specifications ...................................................................6
Dimensions (Top, Side, Front) ...........................................7
Safety Message Alert Symbols ....................................8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 21
Engine Operating Panel ............................................. 22-23
OutputTerminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
OutputTerminal Panel Connections ........................... 30-31
Pre-Setup .................................................................. 32-35
Generator Start-up Procedure (Manual) ..................... 36-37
Generator Start-up Procedure (Auto Mode) .................... 38
Generator Shut-Down Procedure .................................... 39
Maintenance (Engine) ................................................ 40-41
JacketWater Heater/battery Charger (Option) ................ 42
Maintenance (Trailer) ................................................. 43-46
TrailerWiring Diagram ..................................................... 47
GeneratorWiring Diagram ............................................... 48
EngineWiring Diagram ................................................... 49
GeneratorTroubleshooting .............................................. 50
Engine ControllerTroubleshooting ................................... 51
Explanation of Code in Remarks Column ....................... 52
Suggested Spare Parts .................................................. 53
Terms and Condition of Sale — Parts ............................ 88
Specification and part
NOTE
number are subject to
change without notice.
PAGE 4 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
Dealeraccountnumber
❒
❒
❒
❒
❒
❒
Dealernameandaddress
Shipping address (if different than billing address)
Returnfaxnumber
Applicable model number
Quantity,part number and description of each part
Specifypreferredmethodofshipment:
✓
✓
✓
✓
✓
✓
FedEx or UPS Ground
FedEx or UPS Second Day or Third Day
FedEx or UPS Next Day
Federal Express Priority One
DHL
Note:Unlessotherwiseindicatedbycustomer, all
orders are treated as “Standard Orders”, and will
ship within 24 hours.We will make every effort to
ship “Air Shipments” the same day that the order is
received, if prior to 2PM west coast time. “Stock
Orders” must be so noted on fax or web forms.
Truck
Place Your Parts Order Via Web or Fax
For Even More Savings!
Here’s how to get help...
Please have the model and serial number
on hand when calling.
(Domestic USA Dealers Only)
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
Email: [email protected]
800-421-1244
FAX: 310-632-2656
Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Standard
orders
Stock orders
PARTS DEPARTMENT
800-427-1244
310-537-3700
SERVICE DEPARTMENT
800-835-2551
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
310-537-3700, EXT. 279
($750 list and above)
FAX: 800-672-7877
FAX: 310-637-3284
Fax
3%
5%
10%
10%
Web
FAX: 310-638-8046
Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
FAX: 310-638-8046
FAX: 310-638-8046
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE:DISCOUNTSARESUBJECTTOCHANGE
MQPOWER
Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
INTERNET:www.mqpower.com
Toll-free FAX — 800-6-PARTS-7 (800/672-7877)
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 5
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DCA-100SSVU — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA-100SSVU
Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection
Phase
Star with Neutral/Zig Zag
3
110 KVA (88 KW)
100 KVA (80 KW)
120, 127, 139, 240, 254, and 277V
208, 220, 240, 416, 440, and 480V
60 Hz
Standby Output
Prime Output
Voltage — 1Ø
Voltage — 3Ø
Frequency
1800 rpm
Speed
0.8
Power Factor
Dry Weight
4,035 lbs. (1,830 kg.)
4,675 lbs. (2,120 kg.)
Wet Weight
Table 2. Engine Specifications
VOLVO PENTA TAD520GE
4 cycle, water-cooled, direct injection, turbo-charged
4 cylinders
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Starting
4.25 in. x 5.12 in. (108 mm x 130 mm)
290 cu. in. (4.76 liters)
Electric 12VDC
5.2 gal. (19.7 liters)
Coolant Capacity
Lube Oil Capacity
Fuel Type
3.4 gal. (13 liters)
#2 Diesel Fuel
63 gal. (240 liters)
Fuel Tank Capacity
Fuel Consumption
Battery
6.02 gal. (22.8 L)/hr at full load
12V-128 AH
PAGE 6 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — DIMENSIONS (TOP, SIDE AND FRONT)
Dimension ft. (mm.)
20.08 in. (3,050 mm.)
5.12 in. (1,400 mm.)
3.31 in. (1,100 mm.)
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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 7
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DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
appear throughout this manual, and will be referenced in
conjunction with Safety "Message Alert Symbols".
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.
This Owner's Manual has been
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power Model DCA-100SSVU
Whisperwatt™ Generator.
WARNING - LETHAL EXHAUST GASES
NOTE
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH if inhaled. NEVER operate this
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING
WARNING - BURN HAZARDS
Engine components can generate extreme
heat.To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
PAGE 8 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
ALWAYS wear approved respiratory
protection.
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the engine ON/OFF
switch (MPEC) in the OFF/RESET
position when the generator is not in use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 9
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DCA-100SSVU — RULES FOR SAFE OPERATION
■
■
ALWAYS check the machine for loosened threads or bolts
before starting.
DANGER - READTHIS MANUAL!
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.
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
The following safety guidelines should always be used when
operating the DCA-100SSVUWhisperwatt™ AC Generator.
HighTemperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.
General Safety:
■
DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
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 is
restricted it will cause serious
damage to the generator or
engine and may cause injury
to people. The generator
engine gives off DEADLY
■
■
This equipment should not be operated by persons under
18 years of age.
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.
carbon monoxide gas.
■
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
NEVER run engine without air filter.Severe engine damage
may occur.
DO NOT leave the generator running in the manual mode
unattended.
NEVER operate this equipment under the influence or
drugs or alcohol.
Refer to the VOLVO Engine Owner's Manual for engine
technical questions or information.
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.
■
■
■
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.
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
PAGE 10 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
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.
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
The following safety recommendations should also be
followed:
terminals, insufficient tightening of the terminal connections
WET
HANDS
may cause damage to the generator
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
and electrical shock.
NEVER grab or touch a live power
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and
local codes before operating generator. Severe injury or
DEATH! by electrocution can result from operating an
ungrounded generator.
cord with wet hands.
POWER
CORD
(POWER ON)
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
Electrical Safety
Backfeed to a utility system can
cause electrocution and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the National Electrical Code (NEC) and local codes
before operating generator.
■
■
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 6.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
is being transfer to a load.
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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 11
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DCA-100SSVU — RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
■
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:
can cause severe injury or even death through physical
contact with live circuits. Turn all circuit breakers OFF
■
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation, always wear safety
glasses.
before performing maintenance on the generator.
■
■
■
■
NEVER lubricate components or attempt service on a
running machine.
Use well insulated gloves when picking up the battery.
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
DANGER - EXPLOSION HAZARDS
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
The risk of an explosion exists when performing service
on the battery.To avoid severe injury or DEATH:
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
DO NOT drop the battery.There
is the possibility of risk that the
battery may explode.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always
replace broken parts.
■
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.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
■
ALWAYS keep the battery charged. If the battery is not
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
charged a buildup of combustible gas will occur.
■
■
ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■
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.
■
■
In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
PAGE 12 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — RULES FOR SAFE OPERATION
Towing &Transporting Safety
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
■
■
■
Place chock blocks underneath wheel to prevent rolling,
while parked.
The following list of safety precautions should be followed
when towing your generator:
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
CAUTION - FOLLOWTOWING REGULATIONS
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.
Trailer should be adjusted to a level position at all times
when towing.
■
■
Raise and lock trailer wheel stand in up position when
transporting.
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
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.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed Towing & Transporting Safety
guidelines for basic towing techniques.
■
Place support blocks underneath the trailer’s bumper to
prevent tipping, 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.”
■
■
Avoid sharp turns to prevent rolling.
DO NOT transport generator with fuel in tank.
■
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
Emergencies
■
■
■
ALWAYS know the location of the
nearest fire extinguisher.
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 know the location of the
nearest and first aid kit.
■
■
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS know the location of the
nearest phone or keep a phone on
the job site, in case of emergencies.
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS have easy access to the phone
numbers of the nearest Ambulance, Doctor
and Fire Department. This information will
be invaluable in the case of an emergency.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
z
z
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 13
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DCA-100SSVU — GENERATOR DECALS
The DCA-100SSVU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for
operator safety and maintenance information. The illustration below and on the preceding page show the decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
Figure 2. Generator Decals
PAGE 14 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 15
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DCA-100SSVU — INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 16 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — INSTALLATION
Outdoor Installation
Generator Grounding
Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to
bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH
generator is on secure level ground so that it cannot slide or ground.
shift around. Also install the generator in a manner so that
Article 250 (Grounding) of the National Electrical Code (NEC)
the exhaust will not be discharged in the direction of nearby
provides guide lines for proper grounding and specifies that
homes.
the cable ground shall be connected to the grounding system
The installation site must be relatively free from moisture of the building as close to the point of cable entry as
and dust. All electrical equipment should be protected from practical.
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
grounding requirements:
NEC articles 250-64(b) and 250-66 set the following
Foreign materials such as dust, sand, lint and abrasive
1. Use one of the following wire types to connect the
materials have a tendency to cause excessive wear to
generator to earth ground.
engine and alternator parts.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
CAUTION - EXHAUST HAZARD
2. When grounding the generator (Figure 4) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside.The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
NOTE
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
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DCA-100SSVU — GENERAL INFORMATION
Open Delta Excitation System
DCA-100SSVUWhisperwatt™ Series Familiarization
Generator
The DCA-100SSVU generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
The MQ Power Model DCA-100SSVU is a 80 kW generator
(Figure 5) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other industrial
and construction machinery.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■
■
■
■
■
■
■
■
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Engine Speed Switch
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.
Panel Light/Panel Light Switch
Auto ON/OFF Engine Controller (MPEC)
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Generator Control Panel
The “Generator Control Panel” is provided with the following:
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.
■
■
■
■
■
■
■
■
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Voltage Regulator
3-Pole, 250 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Engine
The DCA-100SSVU is powered by a 6 cylinder, water cooled,
direct injection, turbocharged VOLVO Model PENTA
TAD520GE Diesel Engine.This engine is designed to meet
every performance requirement for the generator.Reference
Table 1 for engine specifications.
■
■
■
■
■
■
■
Automatic Voltage Regulator
CurrentTransformer
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
Voltage Rectifer
Starter Relay
Engine Controller (Computer Controlled)
Voltage Selector Switch
Electric Governor System
The electric governor system controls the RPMs of the en-
gine. When the engine demand increases or decreases, the
governor system regulates the frequency variation to .25%.
OutputTerminal Panel
The “Output Terminal Panel” is provided with the following:
Extension Cables
■
■
■
■
■
■
■
Three 120/240V output receptacles (CS-6369), 50A
Three auxilliary circuit breakers, 50A
Two 120V output receptacles (GFCI), 20A
Two GFCI circuit breakers, 20A
Five output terminal lugs (3Ø power)
Battery Charger (Optional)
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.
Water Heater (Optional)
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DCA-100SSVU — MAJOR COMPONENTS
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Air Filter Assembly
1
2
3
4
5
Voltage Selector Switch Assembly
Air Filter Assembly
Generator Assembly
Jacket Water Heater/BatteryCharger
Assembly (Option)
6
7
Output Receptacles Assembly
Engine Assembly
8
Battery Assembly
9
Fuel Tank Assembly
Figure 5. Major Components
10
11
12
Circuit Breaker Assembly
Generator Control Panel Assembly
Engine Control Panel Assembly
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DCA-100SSVU — GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The definitions below describe the controls and functions of
the DCA-100SSVU Generator Control Panel (Figure 6).
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
The Control Box is equipped with the following major
components:
2. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
■
■
■
■
■
■
Over-Current Relay
Voltage Rectifer (AVR)
Starter Relay
CurrentTransformer
Voltage Selector Switch
Three Phase Circuit Breaker
3. ACVoltmeter – Indicates the output voltage present at
the U,V, and W Output Terminal Lugs.
4. Voltage Regulator Control – Allows 15% manual
adjustment of the generator’s output voltage.
5. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
Remember the overcurrent
relay monitors the current
flowing from the U,V, and W
OutputTerminal Lugs to the
load.
NOTE
In the event of a short circuit or over current condition, it will
automatically trip the 250 amp main breaker.
6. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
To restore power to the Output Terminal Panel, press the
reset button on the overcurrent relay and place the main
circuit breaker in the closed position (ON).
7. Main Circuit Breaker – This three-pole, 250A main
breaker is provided to protect the the U,V,andW Output
Terminal Lugs from overload.
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DCA-100SSVU — ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
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DCA-100SSVU — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of If the engine does not engage (start) by the third attempt,
the DCA-100SSVU Engine Operating Panel (Figure 7).
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.
the engine will be shutdown by the engine controller’s Over
Crank Protection mode. If the engine engages at a speed
(RPM's) that is not safe, the controller will shutdown the
engine by initializing the Over Speed Protection mode.
Also the engine controller will 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.
2. Panel Light Switch – When activated will turn on control
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 44 to 73 psi. (303~503
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.
A. MPEC Control Switch – This switch controls the
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.
4. WaterTemperature Gauge – During normal operation
this gauge be should read between 165° and 203°F.
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
If the generator is to be connected to a building’s AC
power source via 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.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
8. Engine Speed Switch –This switch controls the speed
B. Low Oil Pressure – Indicates the engine pressure has
fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a major fault.
of the engine (low/high).
9. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical row of status LED's (inset),
that when lit, indicate that an engine malfunction (fault)
has been detected.When a fault has been detected the
engine controller will evaluate the fault and all major
faults will shutdown the generator. During cranking
cycle , The MPEC will attempt to crank the engine for
10 seconds before disengaging.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 239°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
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.
E. Overspeed Shutdown – Indicates the engine is running
at an unsafe speed. This is considered a major fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
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DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
OutputTerminal Panel
Output Terminal Familiarization
The OutputTerminal Panel (Figure 8) shown below is located The “OutputTerminal Panel ” (Figure 8) is provided with the
on the right-hand side (left from control panel) of the generator. following:
Lift up on the cover to gain access to receptacles and terminal
lugs.
■
■
■
■
■
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Two (2) 120V GFCI receptacles @ 20 amp
Two (2) GFCI Circuit Breakers @ 20 amps
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Terminal legs “O” and “Ground”
are considered bonded grounds.
NOTE
Figure 8. Output Terminal Panel
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DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
100VAC GFCI Receptacles
Each auxilliary receptacle is protected by a 50 amp circuit
breaker.These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
OutputTerminal Lugs.
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker.These breakers are located directly above the GFCI
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 11) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob counter-
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the Test Button (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11.Voltage Regulator Control Knob
Removing the Plastic Face Plate (HardWire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock DualVoltage 120/240VAC Receptacles
There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 10) provided on the output
terminal panel.These receptacles can only be accessed
when the voltage selector switch is placed in the single-
phase 240/120 position.
Figure 12. Plastic Face Plate (OutputTerminal Lugs)
Figure 10. 120/240VTwist-Lock
Auxiliary Receptacles
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DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
Connecting Loads
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Loads can be connected to the generator by the Ouput
Terminal Lugs or the convenience receptacles (Figure 13).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a
3-pole, 250A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Figure 14. Over Current Relay
Figure 13. Connecting Loads
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DCA-100SSVU — LOAD APPLICATION
Three Phase Load
Single Phase Load
When calculating the power requirements for 3-phase power
Always be sure to check the nameplate on the generator
use the following equation:
and equipment to insure the wattage, amperage, frequency
,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybedeterminedbymultiplying
voltage by amperage by 1.732.
NOTE
If wattage is not given on the
equipment's
name
plate,
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
NOTE
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
Table 5. Power Factor By Load
Type Of Load
Power Factor
■
■
■
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Common power tools
0.8
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Current in
Amperes
At 100
Volts
At 200
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
DANGER - ELECTRICAL SYSTEM HAZARDS
7.5
10
15
20
900
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.
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-100SSVU — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 16) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
Table 8 describes the generator’s current output capability
for both 1Ø-phase and 3Ø phase applications.
Table 8. Generator Maximum Amps
Model
DCA100SSVU
Maximum Amps
222.2 amps (4 wire)
Rated Voltage
Single Phase
120 Volt
Single Phase
240 Volt
111.1 amps (4 wire)
241 amps
Three Phase
240 Volt
Three Phase
480 Volt
120 amps
Figure 16. Voltage Selector Switch
Voltage Selector Switch Locking Button
GFCI Receptacle Load Capability
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
The load capability of the GFCI receptacles is directly re-
lated to the voltage being supplied at either the output termi-
nals or the 2 twist lock auxiliary receptacles.
Tables 9 and 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 recep-
tacles.
CAUTION - CHANGINGVOLTAGES
NEVER change the position of the voltage selector switch
while the engine is running.ALWAYS place circuit breaker
in the open position before selecting voltage.
Table 9. 1
Ø
GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
Available Load
Current (Amps)
Generator OutputVoltages
GFCI Duplex NEMA
5-20R 120V
1Ø 240/120V
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 16). 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.
57.7
56.5
55.3
54.1
52.9
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
Table 10. 3Ø GFCI Receptacle Load Capability
Table 7. Voltages Available
Three Phase
KVA in Use
Available Load
(UVWO Terminals)
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
208V
220V
240V
416V
440V
254V
480V
277V
3Ø 240/480V
(Switchable)
100
95.8
91.7
87.5
83.4
0
Single Phase
(Switchable)
120V
127V
139V
240V
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle
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DCA-100SSVU — GAUGE READING
How to Read the OutputTerminal Gauges.
Reading Amperage
The gauges and selector switches on the control panel To determine the amperage at a terminal lug, set the
DO NOT effect the generator output. They are provided to AC Ammeter Change-Over Switch to the appropriate
help observe how much power is being supplied at the setting (Figure 20) to activate the AC Ammeter Gauge
Output terminals lugs.
(Figure 21) and read the available amperage at the terminal
lug.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 17) to the position which produces For example, to measure the amperage at the U
the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the volt-
terminal lug, set the AC Ammeter Change-Over Switch to
U and read the AC Ammeter Gauge.
age selector switch.)
Figure 17. Voltage
Selector Switch 240/
139VThree Phase
Position
Figure 21. AC Ammeter
(Amp reading on U lug)
Figure 20. AC Ammeter
Change-Over Switch
For 3Ø 208V/1Ø,120V, place
NOTE
the Voltage Selector Switch
in the 3 Phase 340/139
position.
The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.
NOTE
ReadingVoltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 18) to activate the AC Voltmeter Gauge
(Figure 19) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the ACVoltmeter Gauge.
Figure 18. AC Voltmeter
Change-Over Switch
Figure 19. ACVoltmeter Gauge
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DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V OutputTerminal Lug Voltages
Various output voltages can be obtained using the Output
Terminal Lugs.. The voltages at the terminals are depen-
dent on the position of the Voltage Selector Switch and the
adjustment of the Voltage Regulator Control Knob.
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 25.
Use this position for
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3Ø 240/139 OutputTerminal Lug Voltages
Figure 25. Voltage Selector
Switch 3Ø-208V/1Ø-120V
Three-Phase Position
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in (Figure 22).
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 26.
Figure 22. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
shown in (Figure 23).
Figure 26. Output Terminal Lugs
3Ø-208V/120V Connections
3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
To achieve a 3Ø 208V output
the voltage selector switch
must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.
Figure 23. Output Terminal Lugs
240/139VThree Phase Connections
NOTE
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
Figure 24. Voltage Regulator Knob (139V/240V)
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DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 OutputTerminal Lug Voltages
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 27.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 29.
Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position
Figure 29. Voltage Selector Switch 240/120V
Single-Phase Position
2. Connect the load wires to the OutputTerminal Lugs as
2. Connect the load wires to the OutputTerminal Lugs as
shown in Figure 28.
shown in (Figure 30).
BLUE
GREEN
BLACK
RED
WHITE
BLUE
GREEN
BLACK
RED
WHITE
U
V
O
W
U
V
O
W
NOT USED
240V
120V
277V
480V
480V
GROUND CONNECTION
MUST BE USED
AT ALL TIMES
GROUND CONNECTION
MUST BE USED
AT ALL TIMES
480V
277V
120V
277V
Figure 30. Output Terminal Lugs
1Ø-240V/120V Connections
Figure 28. Output Terminal Lugs
480/277VThree Phase Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.
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DCA-100SSVU — SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 250 amp,
main circuit breaker is provided to protect the U,V, and W
OutputTerminals from overload.In addition two single-pole,
20 amp GFCI circuit breakers are provided to protect the
GFCI receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 9 for proper
selection of engine oil.
Refilling the Fuel System
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
Figure 30. Engine Oil Dipstick
This generator has an internal fuel tank located inside the
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31). ALWAYS fill the fuel tanks with clean
fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their
capacities.
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Volvo Engine Owner's Manual. Oil should be warm
before draining.
Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Other types of motor oils may be substituted if they meet
the following requirements:
■
■
■
■
API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF
Figure 31. Internal Fuel Tank System
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DCA-100SSVU — SETUP
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
3. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel cap
and fill tank (Figure 33).
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
CAUTION - REFUELINGTHE GENERATOR
ALWAYS place trailer on firm level ground before refueling
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
Figure 33. 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 34).
Figure 32. Only Fill on Level Ground
NOTE
ONLY! use #2 diesel fuel when
refueling.
Figure 34. Full Fuel Tank
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 35).
Figure 35. Fuel Expansion
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DCA-100SSVU — SETUP
Coolant (Antifreeze/Summer Coolant/Water)
Cleaning the Radiator
VOLVO recommendsVOLVO 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 VOLVO Engine Owner's Manual for further details.
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.
Air Cleaner
WARNING - BURN HAZARDS
Periodic cleaning/replacement is necessary. Inspect it in
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.
accordance with the VOLVO Engine Owner's Manual.
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 VOLVO
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 "L" markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 36) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
5.2 Gal. (19.7 liters)
2 Quarts (1.9 liters)
Figure 36. Fan Belt Tension
CAUTION - ROTATING PARTS
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
NEVER place hands near
the belts or fan while the
generator set is running.
Table 13. Anti-Freeze
Operating Temperatures
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
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DCA-100SSVU — SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.
terminals when the MPEC Control Switch is in either
the MANUAL position.ALWAYS make sure that the MPEC
Control Switch is in the OFF/RESET position when
connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or
malfunctions. Always keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
generator is BCI Group 27.
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
If the battery cable is connected
incorrectly, electrical damage to the
NOTE
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
CAUTION - BATTERY SERVICING SAFETY
Battery Cable Installation
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ALWAYS be sure the battery cables (Figure 37) are properly
connected to the battery terminals as shown below.The Red
Cable is connected to the positive terminal of the battery,
and the Black Cable is connected to the negative terminal
of the battery.
Alternator
The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
in short circuit instantaneously resulting the alternator failure.
CAUTION - BATTERY SERVICING SAFETY
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
Figure 37. Battery Connections
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DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)
Before Starting
Manual Start-up Procedure
1. Place the engine speed switch (Figure 41) in the “LOW ”
CAUTION - LETHAL EXHAUST HAZARD
(down) position.
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING - STARTINGTHE GENERATOR
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
Figure 41. Engine Speed Switch (Low)
2. Once the engine glow plugs have been warmed, place
the MPEC Control Switch in the MANUAL position to
start the engine (Figure 42).
1. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 38) in the OFF position prior to starting the engine.
Figure 42. MPEC Control Switch
(Manual Position)
Figure 38. Main, Aux. and GFCI
Circuit Breakers (OFF)
3. Once the engine starts, let it engine run for 1-2 minutes.
Listen for any abnormal noises. If any abnormalities
exists shutdown the engine and correct the problem.
If the engine is running smoothly, place the engine
speed switch (Figure 43) in the “HIGH” (up) position.
2. Make sure the 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 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
Figure 43. Engine Speed Switch (High)
4. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
5. Close all engine enclosure doors (Figure 39).
4. Verify that the Engine Running
status LED on the MPEC unit
(Figure 44) is ON (lit) after the
engine has been started.
Figure 44. Engine Running LED (ON)
Figure 39. Engine Enclosure Doors
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DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)
5. The generator's frequency meter (Figure 45) should be 9. The coolant temperature gauge
displaying the 60 cycle output frequency in HERTZ.
(Figure 50) will indicate the
coolant temperature. Under
normal operating conditions the
coolant temperature should be
between 165~203 °F (74~95 °C),
Green Zone.
Figure 50. Coolant
Temperature Gauge
Figure 45. Frequency Meter (Hz)
10. The tachometergauge(Figure51)
will indicate the speed of the engine
when the generator is operating.
Under normal operating conditions
this speed is approximately 1800
RPM’s.
6. The generator's AC-voltmeter (Figure 47) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 47) to increase or decrease the
desired voltage.
Figure 51. Engine
Tachometer Gauge
11. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 52).
Figure 46.Voltmeter
Figure 47.Voltage Adjust Control Knob
Figure 52. Main, Aux. and GFCI
Circuit Breakers (ON)
7. 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.
12. 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
Figure 48. Ammeter
a load is in use.
(No Load)
Figure 53. Ammeter
(Load)
8. The engine oil pressure gauge
(Figure 49) will indicate the oil
pressure of the engine. Under
normal operating conditions the oil
pressure is approximately 44 to 73
psi. (303~503 kPa). When starting
13. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 49. Oil
Pressure Gauge
the genera
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DCA-100SSVU — GENERATOR START-UP PROCEDURE (AUTO MODE)
Starting (Auto Mode)
When starting generator in AUTO mode use the "Manual
Start-up" procedure except where noted (see below).
DANGER - ELECTRICAL SYSTEM HAZARDS
1. Perform steps 1 through 5 in the Before Starting section.
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.
2. Place the engine speed switch (Figure 54) in the HIGH
position
Figure 54. Engine Speed Switch (High)
CAUTION - BACKUP GENERATOR USE
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
3. Place the MPEC Control Switch (Figure 55) in the AUTO
position
When the generator is set in the
AUTO mode, the generator will
automically start in the event of
Figure 55. MPEC Control Switch (AUTO)
NOTE
comercial power falling below a
4. Continue operating the generator as outlined in the
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
Manual Start-up Procedure (start at step 5).
WARNING - AUTO MODE MAINTENANCE
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
CAUTION - ENGINE SPEED SWITCH
The Engine Speed Switch must be set to the “High”
position when running in the Auto-Start mode.Failing to
set the switch in the proper position can result in damage
to your generator when it turns on.
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DCA-100SSVU — GENERATOR SHUT-DOWN PROCEDURES
Emergency Shutdown Procedure
WARNING - SHUTTING DOWNTHE GENERATOR
1. Place the MPEC Control Switch switch (Figure 57) to
the OFF/RESET position.
NEVER stop the engine suddenly except in an emergency.
2. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 38) circuit
breakers to OFF position.
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 38 to the OFF position.
2. Place the engine speed switch (Figure 56) in the “LOW ”
(down) position.
Figure 56. Engine Speed Switch (Low)
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 57) to the
OFF/RESET position.
Figure 57. MPEC Control Switch (Off/Reset)
5. Verify that the all status LED on the MPEC display
are OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occured during operation.
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DCA-100SSVU — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
1
Replace Engine Oil and Filter *
X
X
Clean Air Filter
ENGINE
Check Fuel Filter/Water Seperator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
X
X
X
X
Clean Radiator and Check Coolant Protection Level*2
3
Replace Air Filter Element *
X
4
Check all Hoses and Clamps *
X
X
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
Check Rotor Rear Support Bearing
X
GENERATOR
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Add "Supplemental Coolant Addatives (SCA'S)" to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the bloby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.
Service Daily
General Inspection
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.
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.UseTable 14 as a general maintenance
guideline Engine Side (Refer to the Engine Instruction
Manual)
Fuel Addition
Air Cleaner
Add diesel fuel (the grade may vary according to season
and locations).
Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.
Removing Water from the FuelTank
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.
Air Cleaner with Dust Indicator
This indicator is attached to the air cleaner. When the air
cleaner element is clogged, air intake restriction becomes
greater and the dust indicator signal shows RED meaning
the element needs changing or service. After changing the
air element, press the dust indicator button to reset the
indicator.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
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DCA-100SSVU — MAINTENANCE
Air Removal
Flushing Out Radiator and Replacing Coolant
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.See the VOLVO Engine
Manual for details.
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant.Open the
radiator cap while draining. Remove the overflow tank
and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
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.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 31.
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufaturer.
Close radiator cap tightly.
Replacing Oil Filter
WARNING - BURN HAZARDS
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
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.
Generator Storage
Cleaning the Fuel Strainer
For longe term storage of the generator the following is
recommended:
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Replacing Fuel Filter
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Replace the fuel filter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
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.
Vent any air.
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DCA-100SSVU — MAINTENANCE
Jacket Water Heater and Internal Battery Charger
120VAC Input Receptacles (OPTIONAL)
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
This generator can be optionally equipped with two 120VAC,
20 amp input receptacles located on the output terminal
panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger.
NOTE
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 58). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.
Figure 56. Battery Charger &
JacketWater Heater Power Connections
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DCA-100SSVU —TRAILER MAINTENANCE
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.
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.
The definitions below describe some of the major components
of a typical trailer that would be used with the DCA-100SSVU
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
Whisperwatt
™
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 16 and Figure 59 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 trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches. Please note that some trailers have a double
axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.
3. GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, in-
cluding 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
7. Coupler - Type of hitch used on the trailer for towing.
on a particular trailer.
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DCA-100SSVU —TRAILER MAINTENANCE
Brakes
Hydraulic Surge Brakes
Trailer brakes should be inspected the first 200 miles of Hydraulic surge brakes (Figure 59) should not require any
operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance
properly. After the first 200 mile interval, inspect the brakes such as shoe and lining replacement. Brake lines should be
every 3,000 miles. If driving over rough terrain, inspect the periodically checked for cracks, kinks, or blockage.
brakes more frequently.
Figure 59 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.
4. With a screwdriver or standard adjusting tool, rotate the
Figure 59. Hydraulic Brake Components
star wheel of the adjuster assembly to expand the brake
shoes.
Actuator
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the surge or push of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
Periodically check and test the surge “actuator” to make
sure that it is functioning correctly. Never use an undersize
actuator.
8. Repeat steps 1 through 7 on the remaining brakes.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Brake line broken or kinked?
Brake lining glazed?
Trailer overloaded?
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
System lubricated?
Replace components.
Replace.
Locking Brakes
Noisy Brakes
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and
linings.
Dragging Brakes
Replace rubber parts
fill with dot 4 fluid.
Enough brake fluid or correct fluid?
PAGE 44 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU —TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Suspension
Tires and wheels are a very important and critical The leaf suspension springs and associated components
components of the trailer. When specifying or replacing the (Figure 60) should be visually inspected every 6,000 miles
trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and
properly matched.
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
CAUTION - EYESIGHT HAZARD
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRINGTRAILERWHEELS
DO NOT attempt to repair or modify a wheel. DO NOT
install in inner tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Figure 60. Major Suspension Components
Table 17. Suspension Torque Requirements
TireWear/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.
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 PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 45
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DCA-100SSVU —TRAILER MAINTENANCE
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 61). DO NOT
torque the wheel lug nuts all the way down.Tighten each
lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 61. Wheel Lug Nuts
Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
PAGE 46 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU —TRAILERWIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 47
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DCA-100SSVU — GENERATORWIRING DIAGRAM
Figure 63. Generator Wiring Diagram
PAGE 48 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — ENGINEWIRING DIAGRAM
ng Diagram
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 49
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DCA-100SSVU —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
No Voltage Output
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Defective Exciter Field?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Check for 17.3 ohms across J & K on CN1
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
Replace if necessary.
High Voltage Output
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Circuit Breaker Tripped
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
PAGE 50 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU —TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor
Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in Controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light is
on.
Inspect/repair wire.
Low coolant level?
Fill coolant level.
Low coolant level light is
on. (Optionally Installed)
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Clean/repair radiator grill.
Close doors.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through radiator?
Doors open?
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
High coolant temperture
light is on.
Generator being overloaded?
Thermostat failure?
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
Controller needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
Engine Controller needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust RPM.
Adjust governor actuator.
Adjust governor controller.
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU light(s) or
on.
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 51
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DCA-100SSVU — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and 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.
QTY. Column
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.
The contents and part numbers listed in the parts section are
subject to change without notice. Multiquip does not
guarantee the availibility of the parts listed.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Sample Parts List:
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.
NO. PART NO. PART NAME
QTY. REMARKS
1
2
2
3
4
12345
BOLT .......................1.... INCLUDES ITEMS W/
WASHER, 1/4 IN. ........... NOT SOLD SEPARATELY
WASHER, 3/8 IN. .... 1.... MQ-45TONLY
HOSE .................... A/R.. MAKE LOCALLY
BEARING ................ 1.... S/N2345B AND ABOVE
*
*
*
12347
12348
12349
Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
NO. Column
Unique Symbols - All items with same unique symbol
Serial Number Break - Used to list an effective serial number
range where a particular part is used.
( , #,
+
, %, or >) in the number column belong to the same
*
assembly or kit, which is indicated by a note in the “Remarks”
column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers 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.
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.
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.
N
OTE
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“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.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, orTBD.
“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.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
PAGE 52 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — SUGGESTED SPARE PARTS
DCA-100SSVUWHISPERWATTGENRATOR
W/VOLVO PENTATAD520GE DIESEL ENGINE
1TO 3 UNITS
Qty.
P/N
Description
1 ......... V20412278.......... HOSE, RADIATOR UPPER
1 ......... V20412279.......... HOSE, RADIATOR LOWER
1 ......... V20412329.......... RADIATOR CAP
1 ......... 0605505070 ........ FUEL CAP
1 ......... V20405794.......... ALTERNATOR 12 VDC
2 ......... V978515 .............. V-BELT, ALTERNATOR
2 ......... V978750 .............. V-BELT, FUEL PUMP
1 ......... V20405779.......... MONITOR, OIL PRESSURE
1 ......... V20405778.......... SENSOR, OIL PRESSURE
1 ......... V20543720.......... TEMP SENSOR UNIT
1 ......... V20412270.......... SENSOR, TEMPERATURE
6 ......... V20549350.......... FILTER, FUEL CARTRIDGE
6 ......... V8159975 ............ FILTER, WATER SEPARATOR
6 ......... V3831236 ............ FILTER, OIL CARTRIDGE
3 ......... V3840033 ............ FILTER, AIR (ELEMENT)
1 ......... 0601808803 ........ CIRCUIT BREAKER, 1P, 120V @ 20A
1 ......... 0601808804 ........ CIRCUIT BREAKER, 2P, 250V @ 50A
2 ......... LY2DUS12VDC .. RELAY
Part number on this Suggested Spare Parts list
may supercede/replace the P/N shown in the text
pages of this book.
NOTE
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 53
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DCA-100SSVU — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 54 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — GENERATOR ASSY.
GENERATOR ASSY.
NO
1
PART NO
PART NAME
QTY.
REMARK
C0110000202
ROTOR ASSY. ...........................1.................... INCLUDES ITEMS W/
*
1-1
FIELD ASSY.
FAN
COUPLING DISK
1
1
5
*
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
8101070033
8101611004
8101015003
0012110030
0042510000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906311
C0130200003
0845041804
8101315202
8101350013
0012110070
0042610000
0041210000
0010110035
0040010000
0041210000
8101310014
8131312014
8101333003
0017106012
8101333003
0010106030
0040006000
0041206000
M2163400003
0012110040
0042610000
0070506306
0012810030
0012810030
8111332014
0600815000
0605000061
0030016000
0040016000
*
*
*
*
*
*
*
*
BALANCING PLATE ..................1.................... PURCHASE ITEM 1-14 AS A SET
HEX HEAD BOLT
WASHER, LOCK
8
8
SET PLATE, RECTIFIER...........1.................... PURCHASE ITEM 1-14 AS A SET
RECTIFIER, PT 3610
SURGE ABSORBER
INSULATORWASHER
INSULATORWASHER
HEX HEAD BOLT
WASHER, LOCK
BALANCING WEIGHT KIT
BEARING, 6311DDU C3
STATOR ASSY.
2
1
1
1
4
4
1
1
1
2
1
1
4
4
4
6
6
6
1
1
1
10
1
2
2
2
1
8
8
1
8
12
1
1
2
2
2
1-10
1-11
1-12
1-13
1-14
1-15
2
*
*
*
*
*
*
3
4
5
6
7
8
9
GROMMET
END BRACKET
FIELD ASSY. EXCITER
HEX HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
SPRINGWASHER
WASHER, FLAT
COVER, BEARING
GASKET, BEARING
COVER, END BRACKET
HEX HEAD BOLT
COVER, END BRACKET
HEX HEAD BOLT
WASHER, LOCK
PLAIN WASHER
COUPLING RING
HEX HEAD BOLT
WASHER, LOCK
BEARING
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A
HEX HEAD BOLT
HEX HEAD BOLT
COVER, FAN
NUT
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 55
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DCA-100SSVU— ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 56 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
CONTROLLER, ECU-9988N
SWITCH
ENGINE SPEED SWITCH
TACHOMETER
OIL PRESSURE GAUGE
WATERTEMPERATURE GAUGE
CHARGING AMMETER
FUEL GAUGE
QTY.
REMARKS
0602202545
0601831340
0601831395
0602120096
0602122097
0602123094
0602121080
0602125090
0601810141
0601831330
M3351100004
0017106040
0027105010
M3223100004
0027105010
M3357200702
M3357201412
0601802149
0601806671
1
1
1
1
1
1
1
1
1
1
9
PANEL LIGHT
SWITCH, PANEL LIGHT
10
11
12
13
14
15
16
17
18
19
ENGINE OPERATING PANEL........................... 1 ............. S/N 7800130 AND ABOVE
HEX HEAD BOLT.............................................. 2 ............. S/N 7800130 AND ABOVE
MACHINE SCREW ........................................... 4 ............. S/N 7800130 AND ABOVE
STOPPER ......................................................... 1 ............. S/N 7800130 AND ABOVE
MACHINE SCREW ........................................... 2 ............. S/N 7800130 AND ABOVE
WIRE HARNESS, ENGINE............................... 1 ............. S/N 7800001~7800129
WIRE HARNESS, ENGINE............................... 1 ............. S/N 7800130 AND ABOVE
FUSE, 10A
FUSE, 15A
1
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 57
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY.(S/N 7800001~7800129)
PAGE 58 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (S/N 7800001~7800129)
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
REMARKS
M321300602
0601808822
0021005080
0601823863
0027104016
0601820671
0027105016
0601806118
0027106016
0601820845
0601820847
0601820846
0601820848
0027104016
0207004000
0601826158
M3213500013
0016906016
M3923100004
S2BG411
CONTROL BOX............................................. 1 ................. S/N 7800001~7800129
CIRCUIT BREAKER, 3P 250A
MACHINE SCREW
RELAY UNIT
MACHINE SCREW
AUTOMATICVOLTAGE REGULATOR
MACHINE SCREW
CURRENTTRANSFORMER, 200:5A............ 3 ................. S/N 7800001~7800129
MACHINE SCREW
OVER CURRENT RELAY.............................. 1 ................. S/N 7800001~7800057
OVER CURRENT RELAY.............................. 1 ................. S/N 7800058~7800129
OVER CURRENT RELAY.............................. 1 ................. S/N 7800001~7800057
OVER CURRENT RELAY.............................. 1 ................. S/N 7800058~7800129
MACHINE SCREW
HEX NUT
CAPACITOR, 0.01uF
CONTROL BOX COVER
HEX HEAD BOLT
SELECTOR SWITCH .................................... 1 ................. S/N 7800001~7800129
KNOB-HANDLE, BLACK
SPACER
SWITCH BRACKET ...................................... 1 ................. S/N 7800001~7800129
EDGING ........................................................ 2 ................. S/N 7800001~7800129
SWITCH BOARD
MACHINE SCREW ....................................... 4 ................. S/N 7800001~7800129
HEX NUT
WASHER, LOCK
WASHER, FLAT
1
4
2
4
1
4
9
6
10
10
11
11
12
13
14
15
16
17
17A
18
19
20
21
22
22A
22B
22C
20
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
2
2
1
1
4
M3276600004
M3213600003
0330000295
M3260500004
0021104015
0207004000
0040004000
0041204000
0330000295
0016906016
M3213600104
0016906016
0016906016
M3223000203
0601807641
0601808988
0601801040
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105016
0027105016
8
1
4
4
4
EDGING ........................................................ 2 ................. S/N 7800001~7800129
HEX HEAD BOLT.......................................... 6 ................. S/N 7800001~7800129
SWITCH COVER ........................................... 1 ................. S/N 7800001~7800129
HEX HEAD BOLT.......................................... 4 ................. S/N 7800001~7800129
HEX HEAD BOLT........................................ 10 ................. S/N 7800001~7800129
CONTROL PANEL
1
1
1
1
1
1
1
1
1
2
4
FREQUENCY METER, 45~65Hz 240V
AC AMMETER, 0~200A/400A
CHANGE-OVER SWITCH, AMMETER
AC VOLTMETER, 0~600V
CHANGE-OVER SWITCH, VOLTMETER
RHEOSTAT (VR) 2W 1K OHM
KNOB
STOPPER
MACHINE SCREW
MACHINE SCREW
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 59
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (CONT. S/N 7800001~7800129)
PAGE 60 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (CONT. S/N 7800001~7800129)
NO
38
39
40
41
42
42
43
43
PART NO
PART NAME
SET SCREW
SNAP RING
RELAY, DC12V
MACHINE SCREW
QTY.
REMARKS
M9220100004
0080200007
0601826031
0027104016
0601823240
0601823240
0027104030
0027104040
LY2DUS12VDC
0601823109
0601824400
0601823768
0601823109
0601824400
0027104020
0602202568
0027105016
0602120475
0016906020
M3246701304
V20405778
V20412270
1
1
1
2
RECTIFIER, DE4503 ........................................ 2 ............. S/N 7800001~7800002
RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800003~7800129
MACHINE SCREW ........................................... 1 ............. S/N 7800001~7800002
MACHINE SCREW ........................................... 1 ............. S/N 7800003~7800129
44
RELAY
1
1
2
1
1
2
4
1
4
1
1
REPLACES P/N 0601827656
44A
4B
45
45A
45B
46
47
48
49
50
RELAY BASE, PTF08A-E
RELAY CLIP, PYCA1
RELAY, LY-2 DC12V
RELAY BASE, PTF08-E
RELAY CLIP, PYCA1
MACHINE SCREW
SPEED CONTROL UNIT
MACHINE SCREW
SPEED SENSOR
HEX HEAD BOLT
51
52
53
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800000~7800129
OIL PRESSURE SENSOR
SENSOR TEMPERATURE
1
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 61
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (S/N 7800130~AND ABOVE)
PAGE 62 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (S/N 7800130~AND ABOVE)
NO
1
1
2
3
4
5
6
7
PART NO
PART NAME
QTY.
REMARKS
M321300902
M321300912
0601808822
0021005080
0601823863
0027104016
0601820671
0027105016
0601806118
0601801124
0027106020
0601820847
0601820848
0027104016
0207004000
0601826158
M3213500213
0016906016
M3270100404
S2BG411
CONTROL BOX................................................. 1 ............. S/N 7800130~7800214
CONTROL BOX................................................. 1 ............. S/N 7800215 AND ABOVE
CIRCUIT BREAKER, 3P 250A
MACHINE SCREW
RELAY UNIT
MACHINE SCREW
AUTOMATICVOLTAGE REULATOR
MACHINE SCREW
CURRENTTRANSFORMER, 200:5A................ 3 ............. S/N 7800130~7800214
CURRENTTRANSFORMER, 200:5A................ 3 ............. S/N 7800215 AND ABOVE
MACHINE SCREW ........................................... 6 ............. REPLACES P/N 0027106016
OVER CURRENT RELAY.................................. 1 ............. S/N 7800130 AND ABOVE
OVER CURRENT RELAY.................................. 1 ............. S/N 7800130 AND ABOVE
MACHINE SCREW
HEX NUT
1
4
2
4
1
4
8
8
9
10
11
12
13
14
15
16
17
17A
17B
17C
18
19
19
20
21
22
22
22A
22B
22C
20
23
23
24
24
24-1
24-2
24-3
25
2
2
1
CAPACITOR, 0.01uF
CONTROL BOX COVER ................................... 1 ............. S/N 7800130 AND ABOVE
HEX HEAD BOLT
SELECTOR SWITCH ........................................ 1 ............. S/N 7800130~AND ABOVE
KNOB-HANDLE, BLACK
DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE
DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE
SPACER
SWITCH BRACKET .......................................... 1 ............. S/N 7800130~7800194
SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800130~7800194
5
M3550002304
M3550002404
M3276600004
M3213600903
M3213601504
0330000295
M3260500004
0021104015
0021104040
0207004000
0040004000
0041204000
0330000295
0016906016
0016906016
M3213601004
M3213601704
0228800210
0228800120
0317700180
0016906016
8
SWITCH BOARD
1
MACHINE SCREW ........................................... 4 ............. S/N 7800130~7800194
MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE
HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE
WASHER, LOCK ............................................... 4 ............. S/N 7800195~AND ABOVE
WASHER, PLAIN .............................................. 4
EDGING ............................................................ 2 ............. S/N 7800001~7800194
HEX HEAD BOLT.............................................. 8 ............. S/N 7800130~7800194
HEX HEAD BOLT.............................................. 6 ............. S/N 7800195~AND ABOVE
SWITCH COVER ............................................... 1 ............. S/N 7800130~7800194
SWITCH COVER ............................................... 1 ............. S/N 7800195~AND ABOVE
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
HEX HEAD BOLT.............................................. 4 ............. S/N 7800001~7800129
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 63
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (CONT. S/N 7800130~AND ABOVE)
PAGE 64 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (CONT. S/N 7800130~AND ABOVE)
NO
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
44A
44B
45
45A
45B
46
47
48
49
50
51
52
PART NO
PART NAME
QTY.
REMARKS
0016906016
M3223000203
0601807641
0601808988
0601801040
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105016
0027105016
M9220100004
0080200007
0601826031
0027104016
0601823240
0027104040
0601827656
PTF08A
HEX HEAD BOLT.............................................15 ............. S/N 7800130~AND ABOVE
CONTROL PANEL
1
1
1
1
1
1
1
1
1
2
4
1
1
1
2
FREQUENCY METER, 45~65Hz 240V
AC AMMETER, 0~200A/400A
CHANGE-OVER SWITCH, AMMETER
AC VOLTMETER, 0~600V
CHANGE-OVER SWITCH, VOLTMETER
RHEOSTAT (VR) 2W 1K OHM
KNOB
STOPPER
MACHINE SCREW
MACHINE SCREW
SET SCREW
SNAP RING
RELAY, DC12V
MACHINE SCREW
RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800130~AND ABOVE
MACHINE SCREW ........................................... 1 ............. S/N 7800130~AND ABOVE
RELAY, LY-2D DC12V
1
RELAY BASE.................................................... 1 .............. REPLACES P/N 0601823109
RELAY CLIP...................................................... 2 .............. REPLACES P/N 0601824400
RELAY, .............................................................. 1 .............. REPLACES P/N 0601823768
RELAY BASE.................................................... 1 .............. REPLACES P/N 0601823109
RELAY CLIP...................................................... 2 .............. REPLACES P/N 0601824400
MACHINE SCREW
SPEED CONTROL UNIT
MACHINE SCREW
SPEED SENSOR
PYCA1
LY2DUS12VDC
PTF08A
PYCA1
0027104020
0602202568
0027105016
0602120475
0016906020
M3260500204
0016906016
0330000180
0330000240
0330000065
M3213601604
0330000225
0027104016
02070004000
M3246701304
M3246701324
V20405778
V20412270
4
1
4
1
1
HEX HEAD BOLT
SET PANEL....................................................... 1 ............. S/N 7800130~AND ABOVE
HEX HEAD BOLT.............................................. 4 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 1 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE
SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE
MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE
HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800130~7800194
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800195~AND ABOVE
53-1
53-2
53-3
54
54-1
55
55A
56
57
58
59
OIL PRESSURE SENSOR
SENSOR TEMPERATURE
1
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 65
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DCA-100SSVU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
PAGE 66 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO
1
1-1
1-2
1-3
2
3
4
5
6
PART NO
M3923200044
V3840033
PART NAME
QTY.
REMARKS
ENGINE & RADIATOR SET .............................. 1 ............. TAD520GE
ELEMENT, AIR CLEANER ................................ 1 ............. REPLACES P/N 0602046622
CARTRIDGE, OIL FILTER ................................ 1 ............. REPLACES P/N 0602041277
CARTRIDGE, FUEL FILTER ............................. 1 ............. REPLACES P/N 0602042560
ENGINE FOOT
ENGINE FOOT
HEX HEAD BOLT
HEX NUT
WASHER, LOCK
RUBBER SUSPENSION
HEX NUT
WASHER, LOCK
RADIATOR BRACKET
HEX HEAD BOLT
SEAL BRACKET
SEAL RUBBER
SEAL RUBBER
HEX HEAD BOLT
ADAPTER
90 DEG. ELBOW
CONNECTOR
ROCKNUT
VALVE
HOSE JOINT
CAP
DRAIN HOSE
DRAIN JOINT
DRAIN HOSE
V3831236
V20549350
M3303200204
M3303200304
0012112040
0030312000
0042512000
0605000450
0030012000
0040012000
M3310201104
0016908020
M3310200814
0283202350
0222900510
0016906020
0602022563
0802022561
0803306590
0603300285
0605511395
0603306395
0802021070
0269200800
M3310600104
0199800800
0193101200
V978515
1
1
4
4
4
2
2
2
2
4
1
1
2
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
OVER FLOW HOSE
V-BELT ALTERNATOR
ALTERNATOR
V-BELT, FUEL PUMP
HOSE RADIATOR, UPPER
HOSE RADIATOR
MONITOR, OIL PRESSURE
TEMPERATURE SENSOR UNIT
V20405794
V978750
V20412278
V20412279
V20405779
V20543720
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 67
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DCA-100SSVU— OUTPUTTERMINAL ASSY.
OUTPUT TERMI
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
5-BLACK
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 68 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
1
5
REMARKS
M3230700003
M9220100304
M9220100404
0039316000
0040016000
0041416000
0016908035
M3238100103
M3236100104
0606010040
0027103010
0030003000
0041203000
0027103010
0030003000
0016906020
0016906016
M3236400004
M3236300004
0016906020
0601808803
0601808804
M1260700304
0222100150
0016906020
0601812598
0601812538
0027104016
0207004000
M3236100213
0010112045
0041212000
M9310200004
0030012000
0603306775
0027104016
0601815194
0027104016
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
5
HEX NUT
WASHER, LOCK
WASHER, FLAT
10
15
20
5
1
1
2
4
4
4
4
4
2
4
1
1
6
2
3
1
1
2
2
2
10
10
1
2
2
2
2
2
4
1
2
HEX HEAD BOLT
TERMINAL COVER
OUTPUTWINDOW
HINGE
MACHINE SCREW
HEX NUT
WASHER, FLAT
MACHINE SCREW
HEX NUT
HEX HEAD BOLT
HEX HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX HEAD BOLT
CIRCUIT BREAKER, 120V,1P 20A
CIRCUIT BREAKER, 250V, 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX HEAD BOLT
RECEPTACLE, 125V 20A X 2
RECEPTACLE, CS6369 250V 50A
MACHINE SCREW
HEX NUT
9
10
11
11A
11B
12
12A
13
14
15
16
17
18
19
20
20-1
21
22
23
24
24A
25
26
27
28
29
30
31
32
33
TERMINAL COVER
HEX HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX NUT
BIND PLUG
MACHINE SCREW
TERMINAL
MACHINE SCREW
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 69
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DCA-100SSVU — ACTUATOR ASSY.
ACTUATOR ASSY.
PAGE 70 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU — ACTUATOR ASSY.
ACTUATOR ASSY.
NO
1
2
3
4
4A
4B
4C
5
5A
6
7
8
9
10
11
12
13
14
PART NO
PART NAME
QTY.
1
1
2
1
1
1
2
1
1
1
2
2
1
3
1
2
REMARKS
0602150070
M3354200004
0021108020
0014208035
0030008000
0040008000
0041208000
0014208035
0041208000
M3354300404
0602180290
0038202000
M3351800004
0041208000
0010106040
0030006000
0041206000
0017106025
ACTUATOR
ACTUATOR BRACKET
FLAT HEAD SCREW
HEX SOCKET HEAD CAP SCREW
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX SOCKET HEAD CAP SCREW
WASHER, FLAT
THROTTLETHREAD
ROD END
HEX NUT
COLLAR
PLAIN WASHER
HEX HEAD BOLT
HEX NUT
WASHER, FLAT
HEX HEAD BOLT
3
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 71
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DCA-100SSVU— BATTERY ASSY.
BATTERY ASSY.
PAGE 72 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
PART NO
PART NAME
QTY.
REMARKS
0602220196
M9310500404
M9103000504
0602220921
0040006000
M3346900804
M3346900604
BATTERY
1
1
1
2
2
1
1
BATTERY SHEET
BATTERY BAND
BATTERY BOLT SET
SPRINGWASHER
BATTERY CABLE
BATTERY CABLE
8
9
9A
10
10A
CABLE .............................................................. 1 ............. MAKE LOCALLY
0017112025
0040512000
0017110020
0040510000
HEX HEAD BOLT
TOOTHEDWASHER
HEX HEAD BOLT
TOOTHEDWASHER
1
1
1
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 73
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DCA-100SSVU— MUFFLER ASSY.
MUFFLER ASSY.
PAGE 74 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2
3
3
4
5
6
7
8
9
10
11
PART NO
PART NAME
MUFFLER
HEX HEAD BOLT
QTY.
1
4
REMARKS
0602300167
0016910025
M3333000713
M333000733
0602320198
M3333200004
0017110040
0017110040
M3330400304
M3330400403
0016908020
0602326061
EXHAUST PIPE ................................................ 1 ............. S/N 7800001~7800012
EXHAUST PIPE ................................................ 1 ............. S/N 7800013 AND ABOVE
GASKET
1
1
4
4
1
1
4
1
GASKET
HEX HEAD BOLT
HEX HEAD BOLT
COVER
BRACKET
HEX HEAD BOLT
U-BOLT SET
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 75
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DCA-100SSVU— FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 76 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— FUELTANK ASSY.
FUEL TANK ASSY.
NO
1
1-1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
1
1
2
4
2
2
2
1
1
1
2
1
2
1
1
2
REMARKS
M3363001002
0605505070
M3363200204
M9310500104
0016908020
0207308000
0222100660
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
0602042266
0602042766
0017110040
0602022567
0602022980
0191401250
0191401050
0191400770
0191302900
0605515198
0605515198
0605515109
0602023200
0017106045
0207006000
0191400135
FUELTANK
CAP, FUEL TANK
TANK BAND
SUPPORTER SHEET
HEX HEAD BOLT
HEX NUT
RUBBER SHEET
DRAIN JOINT
DRAIN BOLT
9
O RING
10
11
12
13
13A
14
15
16
18
18
19
20
21
21
22
23
24
24A
25
HEX HEAD BOLT
DRAIN HOSE
HOSE BAND
WATER SEPARATOR
ELEMENT
HEX HEAD BOLT
90 DEG. ELBOW
SWIVEL
2
2
SUCTION HOSE ............................................... 1 ............. S/N 7800081 AND BELOW
SUCTION HOSE ............................................... 1 ............. S/N 7800082 AND ABOVE
SUCTION HOSE
RETURN HOSE
HOSE BAND ..................................................... 4 ............. S/N 7800081 AND BELOW
HOSE BAND ..................................................... 6 ............. S/N 7800082 AND ABOVE
HOSE BAND
FUEL HAND PUMP............................................1............. S/N 7800082 AND ABOVE
HEX HEAD BOLT...............................................2............. S/N 7800082 AND ABOVE
HEX NUT ...........................................................2............. S/N 7800082 AND ABOVE
SUCTION HOSE ................................................1............. S/N 7800082 AND ABOVE
1
1
2
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 77
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DCA-100SSVU— ENCLOSURE ASSY.
ENCLOSURE ASSY.
ADD THE FOLLOWIN
NUMBER WHEN ORD
INDICATE COLOR O
1-ORANGE
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 78 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO
1
2
3
4
4A
5
6
6A
7
7
PART NO
PART NAME
QTY.
REMARKS
M3413001612
M1413400004
0016908020
M3423001012
M3493105713
0016910025
M3423200104
M3493100304
0016908020
0019208020
M3433000712
M3493200004
0010114040
0030014000
0040014000
0041214000
M344300212
M3443001002
M3493300204
0016910025
0040510000
M3443300203
M3443300903
M3493302603
0207006000
0016908020
0019208020
M3443200113
M3443600104
0207306000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
0019208020
M9310000004
M3463100603
M3463100613
M3493502703
M3463200403
M3493502803
BASE
1
1
2
1
1
6
1
1
UNDER COVER
HEX HEAD BOLT
FRONT FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
COVER, FRONT FRAME
ACOUSTIC SHEET
HEX HEAD BOLT.......................................... 14 ............... S/N 7800001~7800099
HEX HEAD BOLT.......................................... 14 ............... S/N 7800100 AND ABOVE
CENTER FRAME
ACOUSTIC SHEET
HEX HEAD BOLT
HEX NUT
8
8A
9
1
1
12
12
24
24
9A
9B
9C
10
10
10A
11
11A
12
13
13A
14
15
15
16
17
18
18A
19
20
20A
21
21A
22
22
23
24
24
24A
25
25A
WASHER, LOCK
WASHER, FLAT
REAR FRAME................................................. 1 ............... S/N 7800001~7800129
REAR FRAME................................................. 1 ............... S/N 7800130 AND ABOVE
ACOUSTIC SHEET
HEX HEAD BOLT
TOOTHEDWASHER
REAR COVER
DUCT, REAR COVER
ACOUSTIC SHEET
HEX NUT
HEX HEAD BOLT.......................................... 10 ............... S/N 7800001~7800099
HEX HEAD BOLT.......................................... 10 ............... S/N 7800100 AND ABOVE
REAR DOOR
WINDOW PLATE
HEX NUT
WASHER, FLAT
DOOR HANDLE ASSY.
MACHINE SCREW
HEX NUT
1
4
1
1
2
1
12
1
1
10
10
1
4
4
HINGE
WASHER
2
2
HEX HEAD BOLT............................................ 3 ............... S/N 7800001~7800099
HEX HEAD BOLT............................................ 3 ............... S/N 7800100 AND ABOVE
BLIND PLUG
ROOF PANEL.................................................. 1 ............... S/N 7800001~7800214
ROOF PANEL.................................................. 1 ............... S/N 7800215 AND ABOVE
ACOUSTIC SHEET
ROOF PANEL
ACOUSTIC SHEET
2
1
1
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 79
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DCA-100SSVU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE A
ADD THE FOLLOW
NUMBER WHEN OR
INDICATE COLOR
1-ORANGE
2-WHITE
3-SPECTRUM GRE
4-SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 80 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
NO
26
PART NO
PART NAME
QTY.
REMARKS
M3463500404
0016908020
0019208020
M9310000103
M1483600204
M3453200512
M3493411904
0016908055
0019208055
M3453001813
M3453001813
M3493411414
M3453002403
M3493411414
M3453002003
M3493411604
M3453002113
M3493411714
M3453302103
M3493411314
M3453302003
M3453301903
M3493411514
M3453302203
M3493411814
0207006000
0016906016
M9113000002
0021806016
0030006000
M3453700314
0016906016
0019206016
M9110100204
M9116100004
M9110100304
M9116100004
0016908020
0019208020
0601850097
0027208025
M9310000004
0016908020
0040508000
M1465400104
0019208020
OVER COVER, FRONT FRAME
1
27
HEX HEAD BOLT.......................................... 37 ............... S/N 7800001~7800099
HEX HEAD BOLT.......................................... 37 ............... S/N 7800100 AND ABOVE
BONNET CAP ................................................. 1 ............... S/N 7800001~7800214
CHAIN ASSY .................................................. 2 ............... S/N 7800001~7800214
SPLASHER PANEL
ACOUSTIC SHEET
HEX HEAD BOLT............................................ 4 ............... S/N 7800001~7800099
HEX HEAD BOLT............................................ 4 ............... S/N 7800100 AND ABOVE
HEX HEAD BOLT
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
SIDE DOOR
ACOUSTIC SHEET
DUCT
27
28
29
30
1
1
30A
31
31
32
2
1
33
33A
34
1
1
34A
35
35A
36
36A
37
37A
38
39
39A
40
1
1
1
1
1
1
ACOUSTIC SHEET
DUCT
DUCT
ACOUSTIC SHEET
DUCT
ACOUSTIC SHEET
HEX NUT
1
1
1
1
1
40A
41
1
34
5
42
HEX HEAD BOLT
DOOR HANDLE ASSY.
MACHINE SCREW
HEX NUT
43
4
44
16
16
1
44A
45
GUTTER
46
HEX HEAD BOLT............................................ 2 ............... S/N 7800001~7800099
HEX HEAD BOLT............................................ 2 ............... S/N 7800100 AND ABOVE
46
47
HINGE
4
4
4
4
47A
48
WASHER
HINGE
48A
49
WASHER
HEX HEAD BOLT............................................ 9 ............... S/N 7800001~7800099
HEX HEAD BOLT............................................ 9 ............... S/N 7800100 AND ABOVE
49
50
STOPPER
MACHINE SCREW
BLIND PLUG
HEX HEAD BOLT
TOOTHEDWASHER
8
8
8
1
1
51
52
53
53A
54
COVER ............................................................ 1 ............... S/N 7800215 AND ABOVE
HEX HEAD BOLT............................................ 2 ............... S/N 7800215 AND ABOVE
55
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 81
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DCA-100SSVU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
PAGE 82 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
3
1
2
4
4
2
4
1
1
2
1
1
1
1
1
1
REMARKS
0228900785
0229200725
0228901020
0228900990
0228901060
0228900470
0229201100
0229201040
0228800630
0228800970
0228800590
0228100665
0228100370
0228100300
0228100365
0228100280
0228100070
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
9
10
11
12
13
14
15
16
17
1
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 83
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DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
PAGE 84 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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NAMEPLATE AND DECALS ASSY. DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO
1-1
1-2
1-3
PART NO
PART NAME
QTY.
REMARKS
M3552000403
M9520100304
M9520100603
DECAL;OPERATING PROCEDURES ................... 1 .................... M35200040
DECAL; SAFETY INSTRUCTIONS ........................ 1 .................... M92010030
DECAL;CAUTION .................................................. 2 .................... M92010060
CONTROL PANEL, BOX & OPERATING PANEL GROUP
2-1
2-2
2-3
2-4
2-5
2-6
M3550001403
M9520000104
M9520000204
M9520100004
M9520100204
M9520200104
M9520200404
M3550001503
DECAL;CONTROL PANEL .................................... 1 .................... M35000140
PLATE; AMMETER CHANGE-OVER SWITCH ...... 1 .................... M92000010
PLATE;VOLTMETER CHANGE-OVER SWITCH ... 1 .................... M92000020
DECAL;WARNING ELECTRIC SHOCK HAZARD . 1 .................... M92010000
DECAL;CAUTION .................................................. 1 .................... M92010020A
DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020010
DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020040
DECAL; OPERATING PANEL................................. 1 .................... M35000150
2-7
ENGINE & RADIATOR GROUP
3-1
3-2
3-3
3-4
3-5
3-6
M9500000004
M9500100004
M9503000004
M9503000103
M9503100004
M9510100004
DECAL; OIL DRAIN PLUG ..................................... 1 .................... M90000000
DECAL;WATER...................................................... 1 .................... M90010000
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
M1550000703
M3550000304
M9520000004
M9520000504
M9520100004
M9520100404
M9520100503
M9520200003
DECAL;NOTE ........................................................ 1 .................... M15000020
DECAL; RECEPTACLE & CIRCUIT BREAKER ..... 1 .................... M15000070
DECAL;NOTE ........................................................ 1 .................... M35000030
DECAL; GROUND .................................................. 1 .................... M92000000
DECAL; START CONTACT ..................................... 1 .................... M92000050
DECAL;WARNING ELECT.SHOCK HAZARD ....... 1 .................... M92010000
DECAL;DANGER HIGHVOLTAGE ........................ 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
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 85
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DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
PAGE 86 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO
PART NO
PART NAME
MUFFLER GROUP
QTY.
REMARKS
6-1
M9503200004
DECAL;WARNING ENGINE EXHAUST................. 1 .................... M90320000
FUEL TANK GROUP
DECAL; DIESEL FUEL .......................................... 1 .................... M90050000
DECAL; FUEL DRAIN PLUG.................................. 1 .................... M90050010
7-1
7-2
M9500500004
M9500500104
ENCLOSURE GROUP
DECAL; MQ............................................................ 1 .................... M91020000
EMBLEM
MACHINE SCREW
STRIPE
STRIPE
STRIPE
STRIPE
STRIPE
8-1
8-2
9-2A
8-3
8-4
8-5
8-6
8-7
8-8
8-9
M9510200002
0600500090
0021106015
M3560100003
M3560100103
M3560101904
M3560100404
M3560101704
M3560101804
M3560100604
1
2
1
2
2
2
1
1
2
STRIPE
STRIPE
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 87
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Effective:October 1, 2002
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENTTERMS
5. Partsmustbeinnewandresalablecon- forpricedeclinesandaddedchargesforprice
dition,intheoriginalMultiquippackage(if increaseswillnotbemadeforstockonhandat
any), and with Multiquip part numbers thetimeofanypricechange.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
clearlymarked.
Multiquip reserves the right to quote and sell
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIALEXPEDITINGSERVICE
b. Any parts with a limited shelf life A$35.00surchargewillbeaddedtotheinvoice
(such as gaskets, seals, “O” rings, forspecialhandlingincludingbusshipments,
andotherrubberparts)thatwerepur- insuredparcelpostorincaseswhereMultiquip
chasedmorethansixmonthspriorto mustpersonallydeliverthepartstothecarrier.
MINIMUMORDER
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
thereturndate.
LIMITATIONSOFSELLER’SLIABILITY
c. Anylineitemwithanextendeddealer
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
netpriceoflessthan$5.00.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
LIMITATIONOFWARRANTIES
Nowarranties,expressorimplied,aremadein
connection with the sale of parts or trade
accessoriesnorastoanyenginenotmanufac-
tured by Multiquip. Such warranties made in
connectionwiththesaleofnew,completeunits
are made exclusively by a statement of war-
rantypackagedwithsuchunits,andMultiquip
neitherassumesnotauthorizesanypersonto
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification, pending
instructions. If a reply is not received
within five days, the material will be re-
turnedtothesenderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice. Pricechangesareeffectiveonaspe-
cificdateandallordersreceivedonorafterthat
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All datewillbebilledattherevisedprice.Rebates
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 88 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)
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NOTE PAGE
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 89
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVETHE MODEL AND SERIAL
NUMBER ON-HANDWHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
Carson, CA 90746
800-421-1244
FAX:310-632-2656
PARTS DEPARTMENT
800-427-1244
310-537-3700
FAX:800-672-7877
FAX:310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX:310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
WARRANTYDEPARTMENT
800-835-2551,EXT.279
310-537-3700,EXT.279
FAX:310-638-8046
FAX:310-638-8046
Manufactured for Multiquip Inc.
by
DENYO CO., LTD, JAPAN
Your Local Dealer is:
MQPOWER
ADivisionofMultiquipInc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-632-2656
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