Multiquip DCA-100SSJU User Manual

PARTS AND OPERATION MANUAL

Table of Contents

PARTS AND OPERATION MANUAL

MQ POWER

DCA-100SSJU

WHISPERWATT

GENERATOR

(Standard)

PARTS LIST NO. M3870300174

S/N UP TO 7400295-100SSJU

S/N FROM 7400296~100SSJU2

Revision #2 (05/03/01)

MUL TIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 F AX: 310-537-3927 F AX: 310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Table of Contents

HERE'S HOW TO GET HELP

Table of Contents

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

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

SER VICE DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700 FAX: 310/537-3927

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ............................................... 3

Table Of Contents........................................................4

Parts Ordering Procedures .......................................... 5

Rules for Safe Operation .......................................... 6- 9

Towing Rules for Safe Operation ............................... 10

Trailer Safety Guidelines............................................ 11

Trailer Specifications ............................................ 12-13

Trailer Braking System ......................................... 14-15

Trailer Tires & Suspension.................................... 16-17

T railer Wiring Diagram ................................................ 1 8

T railer Troubleshooting (Electric Brak es) .................... 19

T railer T roubleshooting (Hydraulic Brakes) ................. 20

Operation Decals.................................................. 21-22

DCA 100SSJU Specifications ................................... 23

MQ POWER DCA-100SSJU AC GENERATOR

General Information ................................................... 24

Major Components .................................................... 25

Dimensions................................................................ 26

Control Panel Descriptions ................................... 28-29

Engine Operating P anel w/key............................. 30-31

Engine Operating Panel w/MPEC......................... 32-33

Output T erminal Panel Overview........................... 34-41

Installation ............................................................ 42-43

Pre Setup ............................................................. 44-47

Load Application ........................................................ 4 8

Generator Start-up Procedure (Manual)................ 49-51

Generator Start-up Procedure (Auto)......................... 52

Generator Shutdown Procedure................................. 53

Maintenance ......................................................... 54-55

Engine T roubleshooting......................................... 56-57

Generator/Engine T roubleshooting ............................. 58

MPEC T roubleshooting .............................................. 5 9

Explanation of Codes in Remarks Column ................ 60

Suggested Spare Parts ............................................. 6 1

Generator Assembly............................................. 62-63

Control Box Assembly.......................................... 64-67

Engine & Radiator Assembly................................. 68-71

Engine Operating P anel Assembly ........................ 72-73

Output Terminal Assembly..................................... 74-75

Battery Assembly .................................................. 76-77

Muffler Assembly .................................................. 78-79

Fuel Tank Assembly .............................................. 80-81

Enclosure Assembly ............................................. 82-85

Rubber Seal Assembly.......................................... 86-87

Name Plate And Decals ........................................ 88-89

Terms and Condition of Sale — Parts ....................... 90

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

PARTS ORDERING PROCEDURES

Table of Contents

■■

■ Dealer account number

■■

■ Dealer name and address

■■

■ Shipping address (if different than billing address)

■■

■ Return fax number

■■

■ Applicable model number

■■

■ Quantity, part number and description of each part

■■

■ Specify preferred method of shipment:

■■

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)* Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete par t numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered Additional Discount

1-9 items 3% 10+ items** 5%

Get special freight allowances when you order 10 or more line items via FAX!**

■■

■

UPS Ground Service at no charge for freight

■■

■

PS Third Day Service at one-half of actual freight cost

■■

No other allowances on freight shipped by an y other carrier. **Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

Extra Fax Discount

for Domestic USA

Dealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Par ts Depar tment!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE* Fax order discount and UPS special programs revised June 1, 1995

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

Table of Contents

CAUTION:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained

and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-100SSJU portable generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

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

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steeltoed boots and other protective devices required by the job .

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator .

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with burns.

■

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

hot

components can cause serious

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

carbon monoxide gas.

CAUTION

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ P ower f or 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.

■

Whenever necessar y, replace nameplate, operation and safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts before starting.

Always refuel in a well-ventilated area, away from sparks and open flames.

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT smoke around or near

the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

■

NEVER operate the generator in an

explosive atmosphere or near combustible materials. An explosion or fire could result

causing severe

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

bodily harm or even

PAGE 6 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

RULES FOR SAFE OPERATION

Table of Contents

CAUTION

■

NEVER touch output terminals during operation. This is extremely dangerous. Always stop the machine when contact with the output terminals is required.

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator , causing se vere scalding to any persons in the general area of the generator.

DO NOT touch or open any of the below

mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

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.

CAUTION

■

Never use damaged or worn cables when connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’ s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator .

plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator .

DCA-100SSJU — PARTS AND OPERATION MANUAL(STD)— REV. #2 (05/03/01) — PAGE 7

RULES FOR SAFE OPERATION

Table of Contents

■

Battery

CAUTION

The battery contains acids that can cause injury to the eyes and skin. To avoid e ye irritation, alwa ys wear safety glasses . Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

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

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur .

Never over fill the battery with water above the upper limit.

NEVER Run engine without air filter. Severe engine damage may occur.

■

Always service air cleaner frequently to prevent carburetor malfunction.

■

Always disconnect the battery before performing service on the generator .

■

Always be sure the operator is familiar with proper safety precaution s and operations techniques before using generator .

■

Always store equipment properly when not in use. Equipment should be stored in a clean, dry location out of the reach of children.

■

DO NOT lea ve the generator running in the manual mode unattended.

■

DO NOT allow unauthorized people to operate this equipment.

■

Always read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

■

Refer to the engine technical questions or information.

Loading and Unloading (Crane)

John Deere Engine Owner's Manual

for

■

3. Always keep the battery charged. If the battery is not charged a buildup of combustib le gas will occur.

4. Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water , then contact the nearest doctor or hospital, and seek medical attention.

clothing or skin

, rinse skin or clothing

Before lifting, make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient strength.

■

When lifting the generator, always use the balanced center-point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath the machine while lifting.

■

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

PAGE 8 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

RULES FOR SAFE OPERATION

Table of Contents

Transporting

■

Always shutdo wn engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances or bad roads.

■

Always tie-down the generator during transportation by securing the generator .

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See page 10 for basic towing procedures.

Emergencies

■

Always know the location of the nearest and

first aid kit

Also know the phone numbers of the nearest

doctor

and

. Know the location of the nearest telephone.

fire department

fire extinguisher

ambulance

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

■

Always allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous waste.

■

DO NOT pour w aste , oil, coolant or fuel directly onto the ground, down a drain or into any water source.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 9

DCA-100SSJU — TO WING R ULES FOR SAFE OPERATION

Table of Contents

Towing Safety Precautions

CAUTION :

Check with your county or state safety towing regulations department before towing your generator .

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 1) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the tr ailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling f or wear . NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chain to bumper of towing vehicle.

■

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

■

The maximum speed for highway towing is 45 MPH unless posted otherwise. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place rolling, while parked.

■

Place prevent tipping, while parked.

■

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

■

Av oid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual star ts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when tr ansporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

PAGE 10 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 1. Generator with Trailer

DCA-100SSJU — TRAILER-SAFETY GUIDELINES

Table of Contents

CAUTION:

ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury .

It is the purpose of this section to cover the major maintenance components of the trailer . The following trailer components will be discussed in this section:

Brakes

Tires

Lug Nut T orquing

Suspension

Electrical

Brake Troubleshooting T ables

Use the following definitions while reading Table 1.

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

2. Braking System - System employed in stopping the trailer . Typical braking systems are electric, surge, hydraulic, h ydraulic-surge and air.

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

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

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

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

11. Tire Rim - Tires are mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 4 and Figure 5 f or lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3 on page 17). Please not that some trailers hav e a double axle . This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shock transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle. See page 16 for proper wiring connections.

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

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

4. Frame Length - This measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to fender.

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

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 11

DCA-100SSJU — TRAILER-SPECIFICATIONS

Table of Contents

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LEDOM NOITACILPPA LEUF

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51-01-RLRT ,51ACD,21-GLT

X01-RLRT ,51ACD,21-GLT

FX01-RLRT ,51ACD,21-GLT

W522-RLRT 01-ACDONONSBL0022"58"24.BL008

004-WLB 004-WLBONCIRTCELESBL0072"451TSAM/W

FX51-RLRT 51-ACDLAG14ONSBL0072"421"55.BL008

X05-RLRT 52-ACDONONSBL0072"421"55.BL008

FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

TBS52-RLRT 52-ACDONONSBL0992"021"66.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521/58-RLRT ,001,58-ACD

FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

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PAGE 12 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — TRAILER-SPECIFICATIONS

Table of Contents

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DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 13

DCA-100SSJU — TRAILER BRAKING SYSTEM

Table of Contents

Brakes

If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet.

Listed below are some of the advantages that electric brakes have over hydraulic brakes:

An electric brake system can be manually adjusted to

provide the corrected braking capability for varying road and load conditions.

An electric brake system can be modulated to provide

more or less braking force, thus easing the brake load on the towing vehicle.

An electric brake system has very little lag time between

the time the vehicle’s brakes are actuated and the trailer’s brakes are actuated.

An electric brake system can provide an independent

emergency brake system.

Road testing is necessary in order to properly synchronize the towing vehicle’s braking to the trailer’s braking. Brake lockup, grabbiness, or harshness is due to lack of

synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h.. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required. Refer to Table 5 for electric brake troubleshooting guidelines.

Electric Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

PAGE 14 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

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

8. Repeat steps 1 through 6 on the remaining brakes.

DCA-100SSJU — TRAILER BRAKING SYSTEM

Table of Contents

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 3 below displays the major hydraulic/air/surge brake components that will require inspection and maintenance. Inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section. Reference Table 6 for hydraulic brake troubleshooting guidelines.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 15

Figure 3. Hydraulic Brake Components

DCA-100SSJU — TRAILER TIRES & SUSPENSION

Table of Contents

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

CAUTION:

DO NOT attempt to repair or modify a wheel. DO NOT install an 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.

Suspension

The leaf suspension springs and associated components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in preserving tire life. Pressure should be checked cold before operation. DO NO T bleed air from tires when they are hot. Check inflation pressure weekly to insure the maximum tire life and to pre v ent premature tread w ear. Table 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

(Figure 4) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately . Torqued suspension components as detailed in Table 3.

CAUTION:

NOTE

AL WAYS wear safety glasses when remo ving or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 4. Suspension Components

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Table of Contents

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-100SSJU — TRAILER TIRES & SUSPENSION

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FI T ONLY. PARTS MUST ROTATE FREELY.

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAI N NUT

-BOLT ASSEMBLY.

05-XAM03-NIM

Lug Nut T or que 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. Star t all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 5. DO NO T torque the wheel lug n uts all the way down. Tighten each lug nut in 3 separate passes as defined by Table

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically for continued safe operation.

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"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 17

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Figure 5. Lug Nut Tightening Sequence

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

DCA-100SSJU — TRAILER WIRING DIAGRAMS

Table of Contents

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Table of Contents

YMPTOM

DCA-100SSJU — TRAILER-BRAKE TROUBLESHOOTING

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OSSIBLECAUSE

OLUTI ON

NO BRAKES OR INTERMITTENT BRAKES ANY OPEN CI RCUITS OR BROKEN WIRES

ANY SHORT CIRCUIT S

FAULTY CONTROLLER

ANY LOOSE CONNECTIONS

IS THE GROUND WIRE SECURE

WEAK BRAKES OR BRAKES PULL TO ONE SIDE IS THERE GREASE OR OIL ON MAGNETS OR LINI NGS

IS THE CONNECTIONS CORRODED

IS THE BRAKE DRUMS SCORED OR GROOVED

IS THE BRAKES SYNCHRONIZED

LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE,BENT OR BROKEN

IS THE BRAKE DRUMS OUT-OF-ROUND

NOISY BRAKES IS THE SYSTEM LUBRICATED

IS THE BRAKE COMPONENTS CORRECT

DRAGGING BRAKES IS THE BEARI NGS OF THE WHEEL ADJUSTED

FIND AND CORRECT

TEST AND CORRECT

FIND AND REPAIR

FIND AND SECURE

CLEAN OR REPLACE

CLEAN AND CORRECT CAUSE OF

CORROSION

MACHINE OR REPL ACE

CORRECT.(SEE PG 8 FOR

SYNCHRONIZ ING

REPLACE COMPONENTS

REPLACE

LUBRICATE

REPLACE AND CORRECT

ADJUST

)

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 19

DCA-100SSJU — TRAILER-BRAKE TROUBLESHOOTING

Table of Contents

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NO BRAKES IS THE BRAKE LINE BROKEN OR KINKED

WEAK BRAKES OR BRAKES PULL TO ONE SIDE IS THE BRAKE LINING GLAZED

IS THE TRAILER OVERLOADED

IS THE BRAKE DRUMS SCORED OR GROOVED

IS THE TIRE PRESSURE CORRECT

IS THE TIRES UNMATCHED ON THE SAME AXLE

LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE,BENT OR BROKEN

IS THE BRAKE DRUMS OUT-OF-ROUND

NOISY BRAKES IS THE SYSTEM LUBRICATED

IS THE BRAKE COMPONENTS CORRECT

DRAGGING BRAKES IS THE BRAKE LINING THICKNESS CORRECT OR IN RIGHT WRONG

POSITION

IS THERE ENOUGH BRAKE FLUID OR CORRECT FLUID

? ? ?

REPAIR OR REPLACE

REBURNISH OR REPLACE

CORRECT WEIGHT

MACHINE OR REPLACE

INFLATE ALL TIRES EQUALLY

MATCH TIRES

REPLACE COMPONENTS

REPLACE

LUBRICATE

REPLACE AND CORRECT

INSTALL NEW SHOES AND LININGS

REPLACE RUBBER PARTS

FILL WITH DOT

FLUID

PAGE 20 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — GENERAT OR DECALS

Table of Contents

The DCA -100SSJU generator is equipped with a number of safety decals . These decals are provided f or operator saf ety and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from y our dealer.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 21

DCA-100SSJU — GENERAT OR DECALS

Table of Contents

PAGE 22 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — SPECIFICATIONS

Table of Contents

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DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 23

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DCA-100SSJU — GENERAL INFORMA TION

Table of Contents

DCA-100SSJU F AMILIARIZATION Generator

The MQ Po wer Model DCA-100SSJU is a 80 kW 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.

Engine Operating Panel

The “Engine Operating Panel” is pro vided with the following:

Tachometer

Water T emperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel level gauge

Engine Speed Switch

Pre-Heat Button

Emergency Stop Button

Battery Switch

Panel Light

Panel Light Switch

Auto Start/Stop Controller

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

V oltmeter Change-Ov er Switch

Pilot Lamp

generator

Open Delta Excitation System

The DCA-100SSJU generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the power to the from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load.

Engine

The DCA-100SSJU is powered by a 4 cycle, water cooled, turbocharged JOHN DEERE 6068 TF 150 This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 13 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-100SSJU generator are addressed on the following pages.

Open-Delta

" excitation system. The open delta

Automatic V oltage Regulator

fixed ceiling

(A VR) is supplied

" and responds

diesel

engine.

Output T erminal Panel

The “Output T erminal P anel” is provided with the f ollowing:

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 250 amps

Over-Current Relay

PAGE 24 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease , the mechanical governor system regulates the frequency variation to ±1.5%. The electronic governor option increases frequency variation to ±0.25%.