Multiquip DCA-100SSVU User Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-100SSVU

60 Hz GENERATOR

PARTS LIST NO. M3870300704F

Revision #0 (11/05/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

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, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual 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 design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-100SSVU WHISPERWATT AC Generator

. Multiquip Inc. reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 3

MQ POWER DCA-100SSVUMQ POWER DCA-100SSVU

MQ POWER DCA-100SSVU

MQ POWER DCA-100SSVUMQ POWER DCA-100SSVU

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

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

Output Terminal Panel Familiarization ........................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Gauge Reading ............................................................... 29

Output Terminal 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

Jacket Water Heater/battery Charger (Option) ................ 42

Maintenance (Trailer) ................................................. 43-46

Trailer Wiring Diagram ..................................................... 47

Generator Wiring Diagram ............................................... 48

Engine Wiring Diagram ................................................... 49

Generator Troubleshooting .............................................. 50

Engine Controller Troubleshooting ................................... 51

Explanation of Code in Remarks Column ....................... 52

Suggested Spare Parts .................................................. 53

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

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 ......................................................

Fuel Tank Assembly .................................................. 76-77

Enclosure Assembly ................................................. 78-81

Rubber Seals Assembly ............................................ 82-83

Nameplate and Decals .............................................. 84-87

Terms and Condition of Sale — Parts ............................ 88

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

74-75

PAGE 4 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ 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:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, 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.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

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, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

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 Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-100SSVU — SPECIFICATIONS

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,detalitnevfles,dleifgnivloveR

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)WK88(AVK011

)WK08(AVK001

042,931,721,021

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V084dna,044,614,042,022,802

.gk038,1(.sbl530,4

)

).gk021,2(.sbl576,4

snoitacificepSenignE.2elbaT

ledoM

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)mm031xmm801(.ni21.5x.ni52.4

)sretil67.4(.ni.uc092

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)sretil0

tarh/)L8.22(.lag20.6 daollluf

PAGE 6 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

Figure 1. Dimensions

DCA-100SSVU — DIMENSIONS (TOP, SIDE AND FRONT)

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm087(.ni17.03F ).mm050,3(.ni80.021

B).mm0

C).mm050,1(.ni43.14H ).mm001,1(.ni13.34

D).mm079(.ni91.83

E).mm050,1(.ni43.14

87(.ni17.03G ).mm004,1(.ni21.55

).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 7

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

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

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-100SSVU

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

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.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

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.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

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.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

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.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the engine ON/OFF

switch (MPEC) in the OFF/RESET position when the generator is not in use.

CAUTION - OVER-SPEED CONDITIONS

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.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 9

DCA-100SSVU — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

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

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.

■

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.

or even

DEATH

! This equipment is to be

DCA-100SSVU Whisperwatt™ AC Generator.

ALWAYS check the machine for loosened threads or bolts

before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

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 performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. 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 carbon monoxide gas.

bodily harm or even death.

NEVER

operate the generator in any

■

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

■

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

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

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.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

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

DO NOT leave the generator running in the unattended.

Refer to the 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.

VOLVO Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

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

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

The following safety recommendations should also be followed:

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 terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. 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.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

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

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

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

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 11

DCA-100SSVU — RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■

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.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

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.

■

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.

■

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.

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

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 keep the battery charged. If the battery is not 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.

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

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

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)

DCA-100SSVU — RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

■

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

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

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.

■

Place while parked.

■

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.

■

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.

■

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.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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 chains to towing vehicle properly.

■

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

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

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)

DCA-100SSVU — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 15

DCA-100SSVU — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

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.

Indoor Installation

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm b. Aluminum - 8 AWG (8.4 mm2) or larger.

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.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried aminimum of 8 ft. into the ground.

) or larger.

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.

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.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 17

DCA-100SSVU — GENERAL INFORMATION

DCA-100SSVU Whisperwatt™ Series Familiarization Generator

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.

Open Delta Excitation System

The DCA-100SSVU 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 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,

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

Tachometer

■

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Engine Speed Switch

■■

■

Panel Light/Panel Light Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

■■

Generator Control Panel

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

■■

■

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)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Selector Switch

■■

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

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.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

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

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-100SSVU is powered by a 6 cylinder, water cooled, direct injection, turbocharged

TAD520GE Diesel Engine

every performance requirement for the generator. Reference Table 1 for engine specifications.

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

Electric Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

Extension Cables

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

VOLVO Model PENTA

. This engine is designed to meet

PAGE 18 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — MAJOR COMPONENTS

Figure 5. Major Components

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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 19

NOTE PAGE

PAGE 20 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

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.

2. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. AC Voltmeter – 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.

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

■

Three Phase Circuit Breaker

■■

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

NOTE

to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

In the event of a short circuit or over current condition, it will

6. Voltmeter Change-Over Switch – This switch allows

automatically trip the 250 amp main breaker.

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

reset

button on the overcurrent relay and place the

circuit breaker in the

7. Main Circuit Breaker – This three-pole, 250A main breaker is provided to protect the the

Terminal Lugs

from overload.

U,V, and W Output

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 21

DCA-100SSVU — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 22 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-100SSVU

1. Panel Light – Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control 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.

4. Water Temperature 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.

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 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

cycle

, The MPEC will attempt to crank the engine for

10 seconds before disengaging.

Engine Operating Panel

(Figure 7).

cranking

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s

Crank Protection

(RPM's) that is not safe, the controller will shutdown the engine by initializing the

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.

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.

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.

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

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

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 fault.

Over

mode. If the engine engages at a speed

fault.

Over Speed Protection

major

fault.

mode.

major

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

F. Engine Running – Indicates that engine is running at

a safe operating speed.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 23

major

fault.

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

lugs.

■■

■

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)

■■

NOTE

Terminal legs “O” and “Ground”

are considered

bonded grounds

” (Figure 8) is provided with the

Figure 8. Output Terminal Panel

PAGE 24 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

100 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These

any

receptacles can be accessed in 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.

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

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

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

voltage regulator control knob

increase

decrease

Figure 11. Voltage Regulator Control Knob

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

(Figure 11) on the

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 Dual Voltage 120/240 VAC 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 when the voltage selector switch is placed in the

phase 240/120 position.

only

be accessed

single-

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 25

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

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 switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convenience receptacles (Figure 13).

main

circuit breaker is provided. Make sure to

Ouput

Over Current Relay

over current relay

An 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 rent relay must be pressed. The over current relay is located in the control box.

(Figure 14) is connected to the main

reset button

Figure 14. Over Current Relay

on the over cur-

Figure 13. Connecting Loads

PAGE 26 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

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

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■■

■

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.

■■

■

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.

■■

■

When connecting an electric drill or other power tools,

■■

pay close attention to the required starting current capacity.

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

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DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 27

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

DCA-100SSVU — GENERATOR OUTPUTS

Voltage Selector Switch

The

voltage selector

switch (Figure 16) is located above

the output terminal panel’s

Hard Wire Hook-up Panel

Generator Amperage

Table 8 describes the generator’s current output capability

. It

for both 1Ø-phase and 3Ø phase applications.

has been provided for ease of voltage selection.

Figure 16. Voltage Selector Switch

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect the generator and load from being switched while the engine is running. To lock the voltage selector switch,

hold

the

red button

located at the bottom of the switch.

press

and

CAUTION - CHANGING VOLTAGES

NEVER change the position of the

voltage selector switch

while the engine is running. ALWAYS place circuit breaker

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.

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 receptacles.

in the open position before selecting voltage.

Generator Output Voltages

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

knob

located on the control panel.

voltage regulator

(VR)

control

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PAGE 28 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — GAUGE READING

How to Read the Output Terminal Gauges.

The gauges and selector switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied at the

Output terminals lugs

Before taking a reading off either gauge, set the

Selector Switch

the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/ 139V position on the voltage selector switch.)

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

Voltage

(Figure 17) to the position which produces

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 20) to activate the (Figure 21) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the U and read the AC Ammeter Gauge.

Figure 20. AC Ammeter

Change-Over Switch

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Figure 21. AC Ammeter (Amp reading on U lug)

For 3Ø 208V/1Ø,120V, place

NOTE

Reading Voltage

To determine the voltage between two terminal lugs, set the

AC Voltmeter Change-Over Switch

setting (Figure 18) to activate the (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 to W-U and read the

AC Voltmeter Change-Over Switch

AC Voltmeter Gauge

the Voltage Selector Switch in the 3 Phase 340/139 position.

to the appropriate

AC Voltmeter Gauge

NOTE

The

ammeter

show a reading when the

Output Terminal Lugs

connected to a load and in use.

gauge will only

are

Figure 18. AC Voltmeter

Change-Over Switch

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 29

Figure 19. AC Voltmeter Gauge

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the

Terminal Lugs

dent on the position of the adjustment of the

Remember the voltage selector switch determines the of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø 240/139 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139

position as shown in (Figure 22).

.. The voltages at the terminals are depen-

Voltage Selector Switch

Voltage Regulator Control Knob

Output

and the

range

3Ø 208V/1Ø120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 25.

2. Connect the load wires to the shown in Figure 26.

Use this position for 3Ø-208 or 1Ø120V.

Figure 25. Voltage Selector Switch 3Ø-208V/1Ø-120V Three-Phase Position

Output Terminal Lugs

Figure 22. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the shown in (Figure 23).

Figure 23. Output Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Output Terminal Lugs

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

NOTE

must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V.

Figure 24. Voltage Regulator Knob (139V/240V)

PAGE 30 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 27.

Figure 27. Voltage Selector Switch 480/277V

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 29.

Figure 29. Voltage Selector Switch 240/120V

Three-Phase Position

2. Connect the load wires to the shown in Figure 28.

BLACK RED

Output Terminal Lugs

BLUE

WHITE

GREEN

2. Connect the load wires to the shown in (Figure 30).

Single-Phase Position

BLACK RED

Output Terminal Lugs

BLUE

WHITE

GREEN

277V

GROUND CONNECTION

BE USED

MUST

AT ALL TIMES

480V

277V

Figure 28. Output Terminal Lugs

480/277V Three Phase Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

NOT USED

240V 120V

GROUND CONNECTION

120V

BE USED

MUST

AT ALL TIMES

Figure 30. Output Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 31

DCA-100SSVU — SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 250 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

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 - REFUELING THE 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

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.

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

■■

trailer frame and may also be equipped with an environmental fuel tank (Figure 31). fresh

#2 diesel fuel.

capacities. 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.

hot

engine can cause a

ALWAYS

fill the fuel tanks with clean

fire

explosion

DO NOT fill the fuel tanks beyond their

Figure 31. Internal Fuel Tank System

PAGE 32 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

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 - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 33).

Figure 33. Fueling the Generator

Figure 32. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

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).

when

Figure 34. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 35).

Figure 35. Fuel Expansion

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 33

DCA-100SSVU — SETUP

Coolant (Antifreeze/Summer Coolant/Water)

VOLVO recommends VOLVO 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.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

WARNING - BURN HAZARDS

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

If adding coolant/antifreeze mix to the

accordance with the VOLVO Engine Owner's Manual.

radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the VOLVO

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

Engine Owner's Manual.

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.

capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

battery terminal disconnected.

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When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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must be

Figure 36. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

PAGE 34 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. 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.

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.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation 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.

CAUTION - BATTERY SERVICING SAFETY

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the the MANUAL position. ALWAYS make sure that the

Control Switch

connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

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.

MPEC Control Switch

is in either

MPEC

is in the OFF/RESET position when

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 37. Battery Connections

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 35

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrision and damage the alternator.

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 ( immediately.

fuel

oil

) lines are defective replace them

DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 38) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

Manual Start-up Procedure

1. Place the engine speed switch (Figure 41) in the “ (down) position.

2. Once the engine glow plugs have been warmed, place

the start the engine (Figure 42).

LOW

Figure 41. Engine Speed Switch (Low)

MPEC Control Switch

in the MANUAL position to

”

Figure 38. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the the been configured for the desired output voltage.

3. Connect the load to the

terminal lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

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).

voltage change-over board

receptacles or

as shown in Figure 13. These load

the

output

3. Once the engine starts, let it engine run for 1-2 minutes.

has

4. Verify that the Engine Running

Figure 42. MPEC Control Switch

(Manual Position)

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 “

Figure 43. Engine Speed Switch (High)

status LED on the MPEC unit (Figure 44) is ON (lit) after the engine has been started.

HIGH

” (up) position.

Figure 39. Engine Enclosure Doors

PAGE 36 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

Figure 44. Engine Running LED (ON)

DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

5. The generator's frequency meter (Figure 45) should be displaying the 60 cycle output frequency in HERTZ.

9. The (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 45. Frequency Meter (Hz)

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.

10. The will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

11. Place the

ON position (Figure 52).

coolant temperature gauge

Figure 50. Coolant

Temperature Gauge

tachometer gauge

main, GFCI

(Figure 51)

, and

aux

. circuit breakers in the

Figure 51. Engine

Tachometer Gauge

Figure 46. Voltmeter

Figure 47. Voltage Adjust Control Knob

7. The ammeter (Figure 48) will indicate applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

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 the genera

zero amps

with no load

Figure 48. Ammeter

(No Load)

Figure 49. Oil

Pressure Gauge

Figure 52. Main, Aux. and GFCI

Circuit Breakers (ON)

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 a load is in use.

Figure 53. Ammeter

(Load)

13. The generator will run until manually stopped or an abnormal condition occurs.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 37

DCA-100SSVU — GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

electrician (transfer)

building’s electrical system may occur without this transfer switch.

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.

NOTE

must install an

switch

CAUTION - BACKUP GENERATOR USE

. Serious damage to the

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

licensed

isolation

in the event of

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 5 in the

2. Place the position

3. Place the position

4. Continue operating the generator as outlined in the

Manual Start-up Procedure

Manual

Before Starting

engine speed switch

Figure 54. Engine Speed Switch (High)

MPEC Control Switch

Figure 55. MPEC Control Switch (AUTO)

(Figure 54) in the HIGH

(Figure 55) in the AUTO

(start at step 5).

section.

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

position when running in the set the switch in the proper position can result in damage to your generator when it turns on.

must be set to the “High”

Auto-Start

mode. Failing to

PAGE 38 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — GENERATOR SHUT-DOWN PROCEDURES

WARNING -

NEVER stop the engine suddenly except in an emergency.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 38 to the OFF position.

2. Place the engine speed switch (Figure 56) in the “

(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

OFF/RESET position.

SHUTTING DOWN THE GENERATOR

MPEC Control Switch

(Figure 57) to the

LOW

Emergency Shutdown Procedure

1. Place the the OFF/RESET position.

2. To shut-down the engine in the event of an emergency, switch the breakers to OFF position.

”

MPEC Control Switch

MAIN, GFCI

and

switch (Figure 57) to

LOAD

(Figure 38) circuit

Figure 57. MPEC Control Switch (Off/Reset)

5. Verify that the 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.

all

status LED on the MPEC display

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 39

DCA-100SSVU — MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

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

Service Daily

If the engine is operating in very 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

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

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.

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.

indicator.

PAGE 40 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

dusty

if these conditions exists.

dry grass

DCA-100SSVU — MAINTENANCE

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the

Manual

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.

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.

Replacing Oil Filter

for details.

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter. After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

VOLVO Engine

Flushing Out Radiator and Replacing Coolant

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.

Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Tighten both cocks and replace the overflow tank. Replace with coolant as recommended by the engine

manufaturer. Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Generator Storage

cool

when flushing out

Cleaning the Fuel Strainer

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.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Vent any air.

For longe term storage of the generator the following is recommended:

Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

Completely drain the oil from the crankcase and refill if necessary with fresh oil.

Clean the entire generator, internal and external. Cover the generating set and store in a clean, dry place. Disconnect the battery. Make sure engine coolant is at proper level. If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 41

DCA-100SSVU — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the

battery charger

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 to apply power to jacket water heater. However, if the generator will be used in 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.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

Figure 56. Battery Charger &

Jacket Water Heater Power Connections

PAGE 42 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-100SSVU

Whisperwatt

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, hydraulic-surge and air.

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

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

™

Generator.

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 (layers) 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 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 16 and Figure 59 for 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. 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.

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

5. Frame Width - Measurement is from fender to fender

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

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

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

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

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 43

DCA-100SSVU — TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 59) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

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.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the 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

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

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

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PAGE 44 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — TRAILER MAINTENANCE

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.

Suspension

leaf suspension

The (Figure 60) 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

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

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.

springs and associated components

Figure 60. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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stnemeriuqeReuqroTnoisnepsuS.71elbaT

PARTS MUST ROTATE FREELY

BOLT ASSEMBLY

05-XAM03-NIM

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 45

DCA-100SSVU — TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (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.

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 61. Wheel Lug Nuts

Tightening Sequence

NOTE

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

PAGE 46 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — TRAILER WIRING DIAGRAM

Figure 62. Trailer/Towing Vehicle Wiring Diagram

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 47

DCA-100SSVU — GENERATOR WIRING DIAGRAM

Figure 63. Generator Wiring Diagram

PAGE 48 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — ENGINE WIRING DIAGRAM

Figure 64. Engine Wiring Diagram

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 49

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.

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 50 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

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.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve )dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidneseca

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

lpeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

?ytridpukcipci

?detarbilacebotsdeenrellortnoCenign

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

sujdA

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 51

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.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. .... 1 ....

3 12348 HOSE .................... A/R .. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

, #, +, %, or >) in the number column belong to the same

(

assembly or kit, which is indicated by a note in the “Remarks” column.

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.

OTE

without notice

WASHER, 1/4 IN. ...........

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.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

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. A blank entry generally indicates that the item is not sold

separately. Other entries will be clarified in the “Remarks” Column.

REMARKS Column

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.

Assembly/Kit

symbol will be included when this item is purchased. Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

range where a particular part is used. Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

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.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

PART NO. Column

Numbers Used - Part numbers can be indicated by a number,

a blank entry, or TBD. 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)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

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.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-100SSVU — SUGGESTED SPARE PARTS

DCA-100SSVU WHISPER WATTGENRATOR

W/VOLVO PENTA TAD520GE DIESEL ENGINE

1 TO 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

NOTE

may supercede/replace the P/N shown in the text pages of this book.

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 53

GENERATOR ASSY.

DCA-100SSVU — GENERATOR ASSY.

PAGE 54 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARK

1 C0110000202 ROTOR ASSY. ...........................1 .................... INCLUDES ITEMS W/

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

2 C0130200003 STATOR ASSY. 1 3 0845041804 GROMMET 2 4 8101315202 END BRACKET 1 5 8101350013 FIELD ASSY. EXCITER 1 6 0012110070 HEX HEAD BOLT 4 7 0042610000 WASHER, LOCK 4 8 0041210000 WASHER, FLAT 4 9 0010110035 HEX HEAD BOLT 6 10 0040010000 SPRING WASHER 6 11 0041210000 WASHER, FLAT 6 12 8101310014 COVER, BEARING 1 13 8131312014 GASKET, BEARING 1 14 8101333003 COVER, END BRACKET 1 15 0017106012 HEX HEAD BOLT 10 16 8101333003 COVER, END BRACKET 1 17 0010106030 HEX HEAD BOLT 2 18 0040006000 WASHER, LOCK 2 19 0041206000 PLAIN WASHER 2 20 M2163400003 COUPLING RING 1 21 0012110040 HEX HEAD BOLT 8 22 0042610000 WASHER, LOCK 8 23 0070506306 BEARING 1 24 0012810030 HEX HEAD BOLT 8 25 0012810030 HEX HEAD BOLT 12 26 8111332014 COVER, FAN 1 27 0600815000 NUT 1 28 0605000061 RUBBER SUSPENSION 2 29 0030016000 HEX NUT 2 29A 0040016000 WASHER, LOCK 2

8101070033 FAN 1 8101611004 COUPLING DISK 5

8101015003 BALANCING PLATE .................. 1 .................... PURCHASE ITEM 1-14 AS A SET

0012110030 HEX HEAD BOLT 8 0042510000 WASHER, LOCK 8

8101026013 SET PLATE, RECTIFIER ........... 1 .................... PURCHASE ITEM 1-14 AS A SET

0601821349 RECTIFIER, PT 3610 2 0601822601 SURGE ABSORBER 1 8001020004 INSULATOR WASHER 1 8001020504 INSULATOR WASHER 1 0010110020 HEX HEAD BOLT 4 0040010000 WASHER, LOCK 4 0601000209 BALANCING WEIGHT KIT 1 0071906311 BEARING, 6311DDU C3 1

FIELD ASSY. 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 55

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

PAGE 56 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0602202545 CONTROLLER, ECU-9988N 1 2 0601831340 SWITCH 1 3 0601831395 ENGINE SPEED SWITCH 1 4 0602120096 TACHOMETER 1 5 0602122097 OIL PRESSURE GAUGE 1 6 0602123094 WATER TEMPERATURE GAUGE 1 7 0602121080 CHARGING AMMETER 1 8 0602125090 FUEL GAUGE 1 9 0601810141 PANEL LIGHT 1 10 0601831330 SWITCH, PANEL LIGHT 1

11 M3351100004 ENGINE OPERATING PANEL........................... 1 ............. S/N 7800130 AND ABOVE

12 0017106040 HEX HEAD BOLT .............................................. 2 ............. S/N 7800130 AND ABOVE

13 0027105010 MACHINE SCREW ........................................... 4 ............. S/N 7800130 AND ABOVE

14 M3223100004 STOPPER ......................................................... 1 ............. S/N 7800130 AND ABOVE

15 0027105010 MACHINE SCREW ........................................... 2 ............. S/N 7800130 AND ABOVE

16 M3357200702 WIRE HARNESS, ENGINE............................... 1 ............. S/N 7800001~7800129

17 M3357201412 WIRE HARNESS, ENGINE............................... 1 ............. S/N 7800130 AND ABOVE

18 0601802149 FUSE, 10A 1 19 0601806671 FUSE, 15A 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 57

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)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)

CONTROL BOX ASSY. (S/N 7800001~7800129)

NO PART NO PART NAME QTY. REMARKS

1 M321300602 CONTROL BOX ............................................. 1 ................. S/N 7800001~7800129

2 0601808822 CIRCUIT BREAKER, 3P 250A 1 3 0021005080 MACHINE SCREW 4 4 0601823863 RELAY UNIT 2 5 0027104016 MACHINE SCREW 4 6 0601820671 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105016 MACHINE SCREW 4

8 0601806118 CURRENT TRANSFORMER, 200:5A ............ 3 ................. S/N 7800001~7800129

9 0027106016 MACHINE SCREW 6

10 0601820845 OVER CURRENT RELAY .............................. 1 ................. S/N 7800001~7800057

10 0601820847 OVER CURRENT RELAY .............................. 1 ................. S/N 7800058~7800129

11 0601820846 OVER CURRENT RELAY .............................. 1 ................. S/N 7800001~7800057

11 0601820848 OVER CURRENT RELAY .............................. 1 ................. S/N 7800058~7800129

12 0027104016 MACHINE SCREW 2 13 0207004000 HEX NUT 2 14 0601826158 CAPACITOR, 0.01uF 1 15 M3213500013 CONTROL BOX COVER 1 16 0016906016 HEX HEAD BOLT 4

17 M3923100004 SELECTOR SWITCH .................................... 1 ................. S/N 7800001~7800129

17A S2BG411 KNOB-HANDLE, BLACK 18 M3276600004 SPACER 8

19 M3213600003 SWITCH BRACKET ...................................... 1 ................. S/N 7800001~7800129

20 0330000295 EDGING ........................................................ 2 ................. S/N 7800001~7800129

21 M3260500004 SWITCH BOARD 1

22 0021104015 MACHINE SCREW ....................................... 4 ................. S/N 7800001~7800129

22A 0207004000 HEX NUT 4 22B 0040004000 WASHER, LOCK 4 22C 0041204000 WASHER, FLAT 4

20 0330000295 EDGING ........................................................ 2 ................. S/N 7800001~7800129

23 0016906016 HEX HEAD BOLT .......................................... 6 ................. S/N 7800001~7800129

24 M3213600104 SWITCH COVER ........................................... 1 ................. S/N 7800001~7800129

25 0016906016 HEX HEAD BOLT .......................................... 4 ................. S/N 7800001~7800129

26 0016906016 HEX HEAD BOLT ........................................ 10 ................. S/N 7800001~7800129

27 M3223000203 CONTROL PANEL 1 28 0601807641 FREQUENCY METER, 45~65Hz 240V 1 29 0601808988 AC AMMETER, 0~200A/400A 1 30 0601801040 CHANGE-OVER SWITCH, AMMETER 1 31 0601806859 AC VOLTMETER, 0~600V 1 32 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 33 0601840073 RHEOSTAT (VR) 2W 1K OHM 1 34 0601840121 KNOB 1 35 M1223100004 STOPPER 1 36 0027105016 MACHINE SCREW 2 37 0027105016 MACHINE SCREW 4

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 59

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)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)

CONTROL BOX ASSY. (CONT. S/N 7800001~7800129)

NO PART NO PART NAME QTY. REMARKS

38 M9220100004 SET SCREW 1 39 0080200007 SNAP RING 1 40 0601826031 RELAY, DC12V 1 41 0027104016 MACHINE SCREW 2

42 0601823240 RECTIFIER, DE4503 ........................................ 2 ............. S/N 7800001~7800002

42 0601823240 RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800003~7800129

43 0027104030 MACHINE SCREW ........................................... 1 ............. S/N 7800001~7800002

43 0027104040 MACHINE SCREW ........................................... 1 ............. S/N 7800003~7800129

44 LY2DUS12VDC RELAY 1 REPLACES P/N 0601827656 44A 0601823109 RELAY BASE, PTF08A-E 1 4B 0601824400 RELAY CLIP, PYCA1 2 45 0601823768 RELAY, LY-2 DC12V 1 45A 0601823109 RELAY BASE, PTF08-E 1 45B 0601824400 RELAY CLIP, PYCA1 2 46 0027104020 MACHINE SCREW 4 47 0602202568 SPEED CONTROL UNIT 1 48 0027105016 MACHINE SCREW 4 49 0602120475 SPEED SENSOR 1 50 0016906020 HEX HEAD BOLT 1

51 M3246701304 WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800000~7800129

52 V20405778 OIL PRESSURE SENSOR 1 53 V20412270 SENSOR TEMPERATURE 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 61

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)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)

CONTROL BOX ASSY. (S/N 7800130~AND ABOVE)

NO PART NO PART NAME QTY. REMARKS

1 M321300902 CONTROL BOX ................................................. 1 ............. S/N 7800130~7800214

1 M321300912 CONTROL BOX ................................................. 1 ............. S/N 7800215 AND ABOVE

2 0601808822 CIRCUIT BREAKER, 3P 250A 1 3 0021005080 MACHINE SCREW 4 4 0601823863 RELAY UNIT 2 5 0027104016 MACHINE SCREW 4 6 0601820671 AUTOMATIC VOLTAGE REULATOR 1 7 0027105016 MACHINE SCREW 4

8 0601806118 CURRENT TRANSFORMER, 200:5A ................ 3 ............. S/N 7800130~7800214

8 0601801124 CURRENT TRANSFORMER, 200:5A ................ 3 ............. S/N 7800215 AND ABOVE

9 0027106020 MACHINE SCREW ........................................... 6 ............. REPLACES P/N 0027106016

10 0601820847 OVER CURRENT RELAY .................................. 1 ............. S/N 7800130 AND ABOVE

11 0601820848 OVER CURRENT RELAY .................................. 1 ............. S/N 7800130 AND ABOVE

12 0027104016 MACHINE SCREW 2 13 0207004000 HEX NUT 2 14 0601826158 CAPACITOR, 0.01uF 1

15 M3213500213 CONTROL BOX COVER ................................... 1 ............. S/N 7800130 AND ABOVE

16 0016906016 HEX HEAD BOLT 5

17 M3270100404 SELECTOR SWITCH ........................................ 1 ............. S/N 7800130~AND ABOVE

17A S2BG411 KNOB-HANDLE, BLACK

17B M3550002304 DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE

17C M3550002404 DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE

18 M3276600004 SPACER 8

19 M3213600903 SWITCH BRACKET .......................................... 1 ............. S/N 7800130~7800194

19 M3213601504 SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE

20 0330000295 EDGING ............................................................ 2 ............. S/N 7800130~7800194

21 M3260500004 SWITCH BOARD 1

22 0021104015 MACHINE SCREW ........................................... 4 ............. S/N 7800130~7800194

22 0021104040 MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE

22A 0207004000 HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE

22B 0040004000 WASHER, LOCK ............................................... 4 ............. S/N 7800195~AND ABOVE

22C 0041204000 WASHER, PLAIN .............................................. 4

20 0330000295 EDGING ............................................................ 2 ............. S/N 7800001~7800194

23 0016906016 HEX HEAD BOLT .............................................. 8 ............. S/N 7800130~7800194

23 0016906016 HEX HEAD BOLT .............................................. 6 ............. S/N 7800195~AND ABOVE

24 M3213601004 SWITCH COVER ............................................... 1 ............. S/N 7800130~7800194

24 M3213601704 SWITCH COVER ............................................... 1 ............. S/N 7800195~AND ABOVE

24-1 0228800210 SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE

24-2 0228800120 SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE

24-3 0317700180 SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE

25 0016906016 HEX HEAD BOLT .............................................. 4 ............. S/N 7800001~7800129

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 63

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)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)

CONTROL BOX ASSY. (CONT. S/N 7800130~AND ABOVE)

NO PART NO PART NAME QTY. REMARKS

26 0016906016 HEX HEAD BOLT ............................................. 15 ............. S/N 7800130~AND ABOVE

42 0601823240 RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800130~AND ABOVE

43 0027104040 MACHINE SCREW ........................................... 1 ............. S/N 7800130~AND ABOVE

44 0601827656 RELAY, LY-2D DC12V 1

44A PTF08A RELAY BASE .................................................... 1 .............. REPLACES P/N 0601823109

44B PYCA1 RELAY CLIP ...................................................... 2 .............. REPLACES P/N 0601824400

45 LY2DUS12VDC RELAY, .............................................................. 1 .............. REPLACES P/N 0601823768

45A PTF08A RELAY BASE .................................................... 1 .............. REPLACES P/N 0601823109

45B PYCA1 RELAY CLIP ...................................................... 2 .............. REPLACES P/N 0601824400

46 0027104020 MACHINE SCREW 4 47 0602202568 SPEED CONTROL UNIT 1 48 0027105016 MACHINE SCREW 4 49 0602120475 SPEED SENSOR 1 50 0016906020 HEX HEAD BOLT 1

51 M3260500204 SET PANEL ....................................................... 1 ............. S/N 7800130~AND ABOVE

52 0016906016 HEX HEAD BOLT .............................................. 4 ............. S/N 7800130~AND ABOVE

53-1 0330000180 EDGING ............................................................ 2 ............. S/N 7800130~AND ABOVE

53-2 0330000240 EDGING ............................................................ 1 ............. S/N 7800130~AND ABOVE

53-3 0330000065 EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE

54 M3213601604 SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE

54-1 0330000225 EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE

55 0027104016 MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE

55A 02070004000 HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE

56 M3246701304 WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800130~7800194

57 M3246701324 WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800195~AND ABOVE

58 V20405778 OIL PRESSURE SENSOR 1 59 V20412270 SENSOR TEMPERATURE 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 65

ENGINE AND RADIATOR ASSY.

DCA-100SSVU— ENGINE AND RADIATOR ASSY.

PAGE 66 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 M3923200044 ENGINE & RADIATOR SET .............................. 1 ............. TAD520GE

1-1 V3840033 ELEMENT, AIR CLEANER ................................ 1 ............. REPLACES P/N 0602046622

1-2 V3831236 CARTRIDGE, OIL FILTER ................................ 1 ............. REPLACES P/N 0602041277

1-3 V20549350 CARTRIDGE, FUEL FILTER ............................. 1 ............. REPLACES P/N 0602042560

2 M3303200204 ENGINE FOOT 1 3 M3303200304 ENGINE FOOT 1 4 0012112040 HEX HEAD BOLT 4 5 0030312000 HEX NUT 4 6 0042512000 WASHER, LOCK 4 7 0605000450 RUBBER SUSPENSION 2 8 0030012000 HEX NUT 2 9 0040012000 WASHER, LOCK 2 10 M3310201104 RADIATOR BRACKET 2 11 0016908020 HEX HEAD BOLT 4 12 M3310200814 SEAL BRACKET 1 13 0283202350 SEAL RUBBER 1 14 0222900510 SEAL RUBBER 2 15 0016906020 HEX HEAD BOLT 6 16 0602022563 ADAPTER 1 17 0802022561 90 DEG. ELBOW 1 18 0803306590 CONNECTOR 1 19 0603300285 ROCKNUT 1 20 0605511395 VALVE 1 21 0603306395 HOSE JOINT 1 22 0802021070 CAP 1 23 0269200800 DRAIN HOSE 1 24 M3310600104 DRAIN JOINT 1 25 0199800800 DRAIN HOSE 1 26 0193101200 OVER FLOW HOSE 1 27 V978515 V-BELT ALTERNATOR 1 28 V20405794 ALTERNATOR 1 29 V978750 V-BELT, FUEL PUMP 1 30 V20412278 HOSE RADIATOR, UPPER 1 31 V20412279 HOSE RADIATOR 1 32 V20405779 MONITOR, OIL PRESSURE 1 33 V20543720 TEMPERATURE SENSOR UNIT 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 67

OUTPUT TERMINAL ASSY.

DCA-100SSVU— OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 68 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 M3230700003 TERMINAL PANEL 1 2 M9220100304 OUTPUT TERMINAL BOLT 5 3 M9220100404 TIE BOLT 5 4 0039316000 HEX NUT 10 5 0040016000 WASHER, LOCK 15 6 0041416000 WASHER, FLAT 20 7 0016908035 HEX HEAD BOLT 5 8 M3238100103 TERMINAL COVER 1 9 M3236100104 OUTPUT WINDOW 1 10 0606010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX NUT 4 11B 0041203000 WASHER, FLAT 4 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601808803 CIRCUIT BREAKER, 120V,1P 20A 2 19 0601808804 CIRCUIT BREAKER, 250V, 2P 50A 3 20 M1260700304 BREAKER FITTING COVER 1 20-1 0222100150 CUSHION RUBBER 1 21 0016906020 HEX HEAD BOLT 2 22 0601812598 RECEPTACLE, 125V 20A X 2 2 23 0601812538 RECEPTACLE, CS6369 250V 50A 2 24 0027104016 MACHINE SCREW 10 24A 0207004000 HEX NUT 10 25 M3236100213 TERMINAL COVER 1 26 0010112045 HEX HEAD BOLT 2 27 0041212000 PLAIN WASHER 2 28 M9310200004 STAY RUBBER 2 29 0030012000 HEX NUT 2 30 0603306775 BIND PLUG 2 31 0027104016 MACHINE SCREW 4 32 0601815194 TERMINAL 1 33 0027104016 MACHINE SCREW 2

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 69

ACTUATOR ASSY.

DCA-100SSVU — ACTUATOR ASSY.

PAGE 70 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — ACTUATOR ASSY.

ACTUATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0602150070 ACTUATOR 1 2 M3354200004 ACTUATOR BRACKET 1 3 0021108020 FLAT HEAD SCREW 2 4 0014208035 HEX SOCKET HEAD CAP SCREW 1 4A 0030008000 HEX NUT 1 4B 0040008000 WASHER, LOCK 1 4C 0041208000 WASHER, FLAT 2 5 0014208035 HEX SOCKET HEAD CAP SCREW 1 5A 0041208000 WASHER, FLAT 1 6 M3354300404 THROTTLE THREAD 1 7 0602180290 ROD END 2 8 0038202000 HEX NUT 2 9 M3351800004 COLLAR 1 10 0041208000 PLAIN WASHER 3 11 0010106040 HEX HEAD BOLT 1 12 0030006000 HEX NUT 2 13 0041206000 WASHER, FLAT 3 14 0017106025 HEX HEAD BOLT 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 71

BATTERY ASSY.

DCA-100SSVU— BATTERY ASSY.

PAGE 72 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0602220196 BATTERY 1 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 0040006000 SPRING WASHER 2 6 M3346900804 BATTERY CABLE 1 7 M3346900604 BATTERY CABLE 1

8 CABLE .............................................................. 1 ............. MAKE LOCALLY

9 0017112025 HEX HEAD BOLT 1 9A 0040512000 TOOTHED WASHER 1 10 0017110020 HEX HEAD BOLT 1 10A 0040510000 TOOTHED WASHER 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 73

MUFFLER ASSY.

DCA-100SSVU— MUFFLER ASSY.

PAGE 74 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0602300167 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4

3 M3333000713 EXHAUST PIPE ................................................ 1 ............. S/N 7800001~7800012

3 M333000733 EXHAUST PIPE ................................................ 1 ............. S/N 7800013 AND ABOVE

4 0602320198 GASKET 1 5 M3333200004 GASKET 1 6 0017110040 HEX HEAD BOLT 4 7 0017110040 HEX HEAD BOLT 4 8 M3330400304 COVER 1 9 M3330400403 BRACKET 1 10 0016908020 HEX HEAD BOLT 4 11 0602326061 U-BOLT SET 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 75

FUEL TANK ASSY.

DCA-100SSVU— FUEL TANK ASSY.

PAGE 76 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 M3363001002 FUEL TANK 1 1-1 0605505070 CAP, FUEL TANK 1 2 M3363200204 TANK BAND 2 3 M9310500104 SUPPORTER SHEET 4 4 0016908020 HEX HEAD BOLT 2 5 0207308000 HEX NUT 2 6 0222100660 RUBBER SHEET 2 7 M9200000003 DRAIN JOINT 1 8 M9200200004 DRAIN BOLT 1 9 0150000018 O RING 1 10 0016906020 HEX HEAD BOLT 2 11 M1363400104 DRAIN HOSE 1 12 0605515198 HOSE BAND 2 13 0602042266 WATER SEPARATOR 1 13A 0602042766 ELEMENT 1 14 0017110040 HEX HEAD BOLT 2 15 0602022567 90 DEG. ELBOW 2 16 0602022980 SWIVEL 2

18 0191401250 SUCTION HOSE ............................................... 1 ............. S/N 7800081 AND BELOW

18 0191401050 SUCTION HOSE ............................................... 1 ............. S/N 7800082 AND ABOVE

19 0191400770 SUCTION HOSE 1 20 0191302900 RETURN HOSE 1

21 0605515198 HOSE BAND ..................................................... 4 ............. S/N 7800081 AND BELOW

21 0605515198 HOSE BAND ..................................................... 6 ............. S/N 7800082 AND ABOVE

22 0605515109 HOSE BAND 2

23 0602023200 FUEL HAND PUMP ............................................ 1 ............. S/N 7800082 AND ABOVE

24 0017106045 HEX HEAD BOLT ............................................... 2 ............. S/N 7800082 AND ABOVE

24A 0207006000 HEX NUT ........................................................... 2 ............. S/N 7800082 AND ABOVE

25 0191400135 SUCTION HOSE ................................................ 1............. S/N 7800082 AND ABOVE

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 77

ENCLOSURE ASSY.

DCA-100SSVU— ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 78 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO PART NO PART NAME QTY. REMARKS

1 M3413001612 BASE 1 2 M1413400004 UNDER COVER 1 3 0016908020 HEX HEAD BOLT 2 4 M3423001012 FRONT FRAME 1 4A M3493105713 ACOUSTIC SHEET 1 5 0016910025 HEX HEAD BOLT 6 6 M3423200104 COVER, FRONT FRAME 1 6A M3493100304 ACOUSTIC SHEET 1

7 0016908020 HEX HEAD BOLT .......................................... 14 ............... S/N 7800001~7800099

7 0019208020 HEX HEAD BOLT .......................................... 14 ............... S/N 7800100 AND ABOVE

8 M3433000712 CENTER FRAME 1 8A M3493200004 ACOUSTIC SHEET 1 9 0010114040 HEX HEAD BOLT 12 9A 0030014000 HEX NUT 12 9B 0040014000 WASHER, LOCK 24 9C 0041214000 WASHER, FLAT 24

10 M344300212 REAR FRAME ................................................. 1 ............... S/N 7800001~7800129

10 M3443001002 REAR FRAME ................................................. 1 ............... S/N 7800130 AND ABOVE

10A M3493300204 ACOUSTIC SHEET 1 11 0016910025 HEX HEAD BOLT 4 11A 0040510000 TOOTHED WASHER 1 12 M3443300203 REAR COVER 1 13 M3443300903 DUCT, REAR COVER 2 13A M3493302603 ACOUSTIC SHEET 1 14 0207006000 HEX NUT 12

15 0016908020 HEX HEAD BOLT .......................................... 10 ............... S/N 7800001~7800099

15 0019208020 HEX HEAD BOLT .......................................... 10 ............... S/N 7800100 AND ABOVE

16 M3443200113 REAR DOOR 1 17 M3443600104 WINDOW PLATE 1 18 0207306000 HEX NUT 10 18A 0041206000 WASHER, FLAT 10 19 M9113000002 DOOR HANDLE ASSY. 1 20 0021806016 MACHINE SCREW 4 20A 0030006000 HEX NUT 4 21 M9110100204 HINGE 2 21A M9116100004 WASHER 2

22 0016908020 HEX HEAD BOLT ............................................ 3 ............... S/N 7800001~7800099

22 0019208020 HEX HEAD BOLT ............................................ 3 ............... S/N 7800100 AND ABOVE

23 M9310000004 BLIND PLUG 2

24 M3463100603 ROOF PANEL .................................................. 1 ............... S/N 7800001~7800214

24 M3463100613 ROOF PANEL .................................................. 1 ............... S/N 7800215 AND ABOVE

24A M3493502703 ACOUSTIC SHEET 1 25 M3463200403 ROOF PANEL 1 25A M3493502803 ACOUSTIC SHEET 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 79

ENCLOSURE ASSY. (CONT.)

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 80 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO PART NO PART NAME QTY. REMARKS

26 M3463500404 OVER COVER, FRONT FRAME 1

27 0016908020 HEX HEAD BOLT .......................................... 37 ............... S/N 7800001~7800099

27 0019208020 HEX HEAD BOLT .......................................... 37 ............... S/N 7800100 AND ABOVE

28 M9310000103 BONNET CAP ................................................. 1 ............... S/N 7800001~7800214

29 M1483600204 CHAIN ASSY .................................................. 2 ............... S/N 7800001~7800214

30 M3453200512 SPLASHER PANEL 1 30A M3493411904 ACOUSTIC SHEET 1

31 0016908055 HEX HEAD BOLT ............................................ 4 ............... S/N 7800001~7800099

31 0019208055 HEX HEAD BOLT ............................................ 4 ............... S/N 7800100 AND ABOVE

32 M3453001813 HEX HEAD BOLT 2 33 M3453001813 SIDE DOOR 1 33A M3493411414 ACOUSTIC SHEET 1 34 M3453002403 SIDE DOOR 1 34A M3493411414 ACOUSTIC SHEET 1 35 M3453002003 SIDE DOOR 1 35A M3493411604 ACOUSTIC SHEET 1 36 M3453002113 SIDE DOOR 1 36A M3493411714 ACOUSTIC SHEET 1 37 M3453302103 DUCT 1 37A M3493411314 ACOUSTIC SHEET 1 38 M3453302003 DUCT 1 39 M3453301903 DUCT 1 39A M3493411514 ACOUSTIC SHEET 1 40 M3453302203 DUCT 1 40A M3493411814 ACOUSTIC SHEET 1 41 0207006000 HEX NUT 34 42 0016906016 HEX HEAD BOLT 5 43 M9113000002 DOOR HANDLE ASSY. 4 44 0021806016 MACHINE SCREW 16 44A 0030006000 HEX NUT 16 45 M3453700314 GUTTER 1

46 0016906016 HEX HEAD BOLT ............................................ 2 ............... S/N 7800001~7800099

46 0019206016 HEX HEAD BOLT ............................................ 2 ............... S/N 7800100 AND ABOVE

47 M9110100204 HINGE 4 47A M9116100004 WASHER 4 48 M9110100304 HINGE 4 48A M9116100004 WASHER 4

49 0016908020 HEX HEAD BOLT ............................................ 9 ............... S/N 7800001~7800099

49 0019208020 HEX HEAD BOLT ............................................ 9 ............... S/N 7800100 AND ABOVE

50 0601850097 STOPPER 8 51 0027208025 MACHINE SCREW 8 52 M9310000004 BLIND PLUG 8 53 0016908020 HEX HEAD BOLT 1 53A 0040508000 TOOTHED WASHER 1

54 M1465400104 COVER ............................................................ 1 ............... S/N 7800215 AND ABOVE

55 0019208020 HEX HEAD BOLT ............................................ 2 ............... S/N 7800215 AND ABOVE

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 81

RUBBER SEALS ASSY.

DCA-100SSVU— RUBBER SEALS ASSY.

PAGE 82 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0228900785 SEAL RUBBER 3 2 0229200725 SEAL RUBBER 1 3 0228901020 SEAL RUBBER 2 4 0228900990 SEAL RUBBER 4 5 0228901060 SEAL RUBBER 4 6 0228900470 SEAL RUBBER 2 7 0229201100 SEAL RUBBER 4 8 0229201040 SEAL RUBBER 1 9 0228800630 SEAL RUBBER 1 10 0228800970 SEAL RUBBER 2 11 0228800590 SEAL RUBBER 1 12 0228100665 SEAL RUBBER 1 13 0228100370 SEAL RUBBER 1 14 0228100300 SEAL RUBBER 1 15 0228100365 SEAL RUBBER 1 16 0228100280 SEAL RUBBER 1 17 0228100070 SEAL RUBBER 1

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 83

NAMEPLATE AND DECALS ASSY.

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

PAGE 84 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

NAMEPLATE AND DECALS ASSY.

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO PART NO PART NAME QTY. REMARKS

1-1 M3552000403 DECAL; OPERATING PROCEDURES ................... 1 .................... M35200040

1-2 M9520100304 DECAL; SAFETY INSTRUCTIONS ........................ 1 .................... M92010030

1-3 M9520100603 DECAL; CAUTION .................................................. 2 .................... M92010060

CONTROL PANEL, BOX & OPERATING PANEL GROUP

2-1 M3550001403 DECAL; CONTROL PANEL .................................... 1 .................... M35000140

2-2 M9520000104 PLATE; AMMETER CHANGE-OVER SWITCH ...... 1 .................... M92000010

2-3 M9520000204 PLATE; VOLTMETER CHANGE-OVER SWITCH ... 1 .................... M92000020

2-4 M9520100004 DECAL; WARNING ELECTRIC SHOCK HAZARD . 1 .................... M92010000

2-5 M9520100204 DECAL; CAUTION .................................................. 1 .................... M92010020A

2-6 M9520200104 DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020010

M9520200404 DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020040

2-7 M3550001503 DECAL; OPERATING PANEL ................................. 1 .................... M35000150

ENGINE & RADIATOR GROUP

3-1 M9500000004 DECAL; OIL DRAIN PLUG ..................................... 1 .................... M90000000

3-2 M9500100004 DECAL; WATER ...................................................... 1 .................... M90010000

3-3 M9503000004 DECAL; WARNING MOVING PARTS ..................... 2 .................... M90300000

3-4 M9503000103 DECAL; WATER * OIL CHECK ............................... 1 .................... M90300010

3-5 M9503100004 DECAL; WARNING HOT COOLANT ....................... 1 .................... M90310000

3-6 M9510100004 DECAL; CAUTION HOT PARTS ............................. 1 .................... M91010000

OUTPUT TERMINAL GROUP

4-1 M1550000204 DECAL; NOTE ........................................................ 1 .................... M15000020

4-2 M1550000703 DECAL; RECEPTACLE & CIRCUIT BREAKER ..... 1 .................... M15000070

4-3 M3550000304 DECAL; NOTE ........................................................ 1 .................... M35000030

4-4 M9520000004 DECAL; GROUND .................................................. 1 .................... M92000000

4-5 M9520000504 DECAL; START CONTACT ..................................... 1 .................... M92000050

4-6 M9520100004 DECAL; WARNING ELECT. SHOCK HAZARD ....... 1 .................... M92010000

4-7 M9520100404 DECAL; DANGER HIGH VOLTAGE ........................ 1 .................... M92010040

4-8 M9520100503 DECAL; WARNING ................................................. 1 .................... M92010050

4-9 M9520200003 DECAL; OUTPUT TERMINAL ................................ 1 .................... M92020000

BATTERY GROUP

5-1 M9500300004 DECAL; - ................................................................ 1 .................... M90030000

5-2 M9500300104 DECAL; + ............................................................... 1 .................... M90030010

5-3 M9510100403 DECAL; CAUTION .................................................. 1 .................... M91010040

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 85

NAMEPLATE AND DECALS ASSY.

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

PAGE 86 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO PART NO PART NAME QTY. REMARKS

MUFFLER GROUP

6-1 M9503200004 DECAL; WARNING ENGINE EXHAUST................. 1 .................... M90320000

FUEL TANK GROUP

7-1 M9500500004 DECAL; DIESEL FUEL .......................................... 1 .................... M90050000

7-2 M9500500104 DECAL; FUEL DRAIN PLUG .................................. 1 .................... M90050010

ENCLOSURE GROUP

8-1 M9510200002 DECAL; MQ ............................................................ 1 .................... M91020000

8-2 0600500090 EMBLEM 1 9-2A 0021106015 MACHINE SCREW 2 8-3 M3560100003 STRIPE 1 8-4 M3560100103 STRIPE 2 8-5 M3560101904 STRIPE 2 8-6 M3560100404 STRIPE 2 8-7 M3560101704 STRIPE 1 8-8 M3560101804 STRIPE 1 8-9 M3560100604 STRIPE 2

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 87

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Retur n Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates

for price declines and added charges for price dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such wr itten statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 88 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

NOTE PAGE

DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 89

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

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, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-mail: mqpower@multiquip.com Internet: www.mqpower.com

Multiquip DCA-100SSVU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual