Multiquip DCA150SSVU User Manual

Download

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

MQ POWER

DCA-150SSVU

WHISPERWATT

GENERATOR

(STANDARD)

PARTS LIST NO. M3870300504

Revision #1 (06/03/03)

MULTIQUIP INC

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

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

. PARTS DEPARTMENT:

SERVICE DEPARTMENT:

PAGE 2 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

HERE'S HOW TO GET HELP

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

PARTS DEPARTMENT

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

SERVICE DEPARTMENT

800-421-1244 FAX: 310- 537-4259

TECHNICAL ASSISTANCE

800-478-1244 FAX: 310- 631-5032

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: 310- 537-1173

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 3

MQ POWER DCA-150SSSVUMQ POWER DCA-150SSSVU

MQ POWER DCA-150SSSVU

MQ POWER DCA-150SSSVUMQ POWER DCA-150SSSVU

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

WINGSWINGS

WINGS

WINGSWINGS

AC GENERAAC GENERA

AC GENERA

AC GENERAAC GENERA

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

Installation ................................................................. 14-15

Towing Safety Precaution ............................................... 16

Trailer Specifications ................................................. 17-19

Generator Decals ....................................................... 20-21

General Information ........................................................22

Major Components ......................................................... 23

Generator Control Panel/Box .......................................... 24

Engine Operating Panel ............................................. 26-27

Output Terminal Panel Familiarization ........................ 28-30

Load Application ............................................................. 31

Generator Outputs ..................................................... 32-33

Gauge Reading ............................................................... 33

Output Ter minal Panel Connections ........................... 34-35

Pre Setup .................................................................. 36-40

Generator Start-up Procedure (Manual) ..................... 41-43

Generator Start-up Procedure (Auto Mode) .................... 44

Generator Shut-Down Procedure .................................... 45

Maintenance .............................................................. 46-48

Trailer Brakes Maintenance ............................................ 49

Trailer Maintenance.................................................... 50-51

Trailer Wiring Diagram ..................................................... 52

Generator Wiring Diagram ............................................... 53

Engine Wiring Diagram (w/ Controller) ............................54

Engine Troubleshooting .............................................. 56-57

Generator Troubleshooting .............................................. 58

Engine Controller Troubleshooting ................................... 59

Explanation of Code in Remarks Column ....................... 60

Suggested Spare Parts .................................................. 61

TORTOR

TOR

TORTOR

Name Plate And Decals ............................................ 62-65

Generator Assembly .................................................. 66-67

Control Box Assembly ............................................... 68-71

Engine & Radiator Assembly..................................... 72-75

Engine Operating Panel Assembly ............................ 76-77

Output Terminal Assembly ......................................... 78-79

Battery Assembly ...................................................... 80-81

Muffler Assembly ...................................................... 82-83

Fuel Tank Assembly .................................................. 84-85

Enclosure Assembly ................................................. 86-89

Rubber Seal Assembly .............................................. 90-91

Terms and Condition of Sale — Parts ............................ 92

Specification and part

NOTE

PAGE 4 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

number are subject to change without notice.

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.

Parts Department

800-427-1244 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Mayco Parts

800-306-2926 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Service Department

800-478-1244 Fax: 310-537-4259

310-537-3700

MQ Power Service Department

800-835-2551 Fax: 310-638-8046

310-537-3700

Warranty Department

800-421-1244, Ext. 279 Fax: 310-537-1173

310-537-3700, Ext. 279

Multiquip’s Main Phone Numbers

800-421-1244 Fax: 310-537-3927

310-537-3700

Place Your Parts Order Via Web or Fax

For Even More Savings!

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.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

MULTIQUIP INC.

18910 WILMINGTON AVENUE POST OFFICE BOX 6254 CARSON, CALIFORNIA 90749 310-537-3700 • 800-421-1244 FAX: 310-537-3927 E-MAIL: mq@multiquip.com WWW: multiquip.com

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

DCA150SSVU — SPECIFICATIONS

ledoMUVSS051-ACD

snoitacificepSrotareneG.1elbaT

epyT

noitcennoCerutamrAlartueNhtiwratSgaZgiZ

esahP

tuptuOybdnatS

tuptuOemirP

egatloV

ycneuqerF

deepS

rotcaFrewoP

rewoPCA.xuA

egatloV

tuptuO

3elgniS

)WK231(AVK561WK69

)WK021(AVK051WK78

V084roV042V021/042

zH06

mpr0081

8.01

zH06,esahPelgniS

V021

)2xWK4.2(WK8.4

rotarenegsuonorhcnysepytdetcetorpnepo,detalitnevfles,dleifgnivloveR

snoitacificepSenignE

ledoM

epyT

srednilyCfo.oN

ekortSxeroB

tuptuOdetaR

tnemecalpsiD

gnitratS

yticapaCtnalooC

yticapaCliOebuL

tarh/)sretil2.23(.lag5.8 daollluf tarh/)sretil5.42(.lag5.6 daol4/3

noitpmusnoCleuF

tarh/)sretil5.81(.lag9.4 daol2/1 tarh/)sretil4.21(.lag3.3 daol4/1

yrettaB

leuF

srednilyc6

cirtcelE

EG027DATATNEPOVLOV

degrahc-obrut,noitcejnitcerid,delooc-retaw,elcyC4

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

mpr0081/PH191

)sretiL51.7(.ni.uc634

)sretL8.32(.lag3.6

)sretiL02(.lag3.5

HA522-V21

leuFleseiD2#

PAGE 6 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 7

DCA150SSVU — 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

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

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

DCA150SSVU WHISPERWATT™ GENERATOR.

Model

HAZARD SYMBOLS

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.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous

carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

NEVER operate this equipment in a confined area or enclosed structure that does not

provide ample free flow air.

Explosive Fuel

Diesel fuel is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent.

DANGER: You WILL be KILLED or

SERIOUSLY injured if you DO NOT follow directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you DO NOT follow directions.

CAUTION: You CAN be injured if you

DO NOT follow directions.

Potential hazards associated with trowel operation will be referenced with " this manual, and will be referenced in conjunction with Safety "

Message Alert Symbols

Hazard Symbols

" which appear throughout

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.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep and

clothing

prevent injury.

fingers, hands, hair

away from all moving parts to

PAGE 8 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the engine ON/OFF switch

in the OFF position, when the trowel is not in use.

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.

This

NOTE

the surrounding environment could be damaged if you do not follow instructions.

generator

, other property, or

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

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

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 9

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

DCA-150SSVU — RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

The following safety guidelines should always be used when operating the DCA-150SSVU Generator:

GENERAL SAFETY

■

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

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact

hot!

with

■

The engine of this generator requires an adequate free flow of cooling air. operate the generator

■

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

■

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

in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

■

ALWAYS make sure generator is properly grounded.

■

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

NEVER use gas piping as an electrical ground.

■

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

components can cause serious burns.

NEVER

■

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.

■

Manufacture does not assume responsibility for any accident due to equipment modifications.

■

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

■

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

■

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

bodily harm or even death.

PAGE 10 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

ALWAYS make sure generator installation is accordance with

national and local electrical codes

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

NEVER power cables or cords

■

NEVER is being transfer to a load.

■

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 5.

■

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

stand in water

while AC power from the generator

Turn all circuit breakers OFF before

lay in wate

DCA-150SSVU — RULES FOR SAFE OPERATION

■

ALWAYS make sure that electrical circuits are properly

grounded

codes before operating generator. Severe electrocution can result from operating an ungrounded generator.

■

ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using generator.

■

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.

■

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

DANGERDANGER

DANGER

DANGERDANGER

generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DANGERDANGER

DANGER

DANGERDANGER

DANGER

DANGERDANGER

per the

National Electrical Code

(NEC) and local

injury

death!

Never use damaged or worn cables when

connecting equipment to the generator. Make sure

power connecting cables are securely connected to the

WET

HANDS

NEVER grab or

touch a live power cord with

wet hands , the possibility exists

of electrical shock, electrocution, and even

death!

POWER

CORD

(POWER ON)

DANGERDANGER

DANGER

DANGERDANGER

■

Backfeed to a utility system can cause 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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the engine

2. Coolant Drain Plug - Removing the coolant drain plug

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

Maintenance Safety

■

electrocution

and or

DO NOT touch or open any of the below

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

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.

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

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

NEVER lubricate components or attempt service on a running machine.

■

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. There exists the possibility of

which can cause severe bodily harm or even death

electrocution, electrical shock or burn,

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 11

■

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.

DCA150SSVU — RULES FOR SAFE OPERATION

■

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

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

■

ALWAYS disconnect the performing service on the generator.

■

ALWAYS be sure the operator is familiar with proper safety precautions when operating the generator set.

■

ALWAYS store equipment properly when not in use.

■

DO NOT leave the generator running in the unattended.

■

DO NOT allow unauthorized people to operate this equipment.

■

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

■

Refer to the questions or information.

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Volvo Engine Manual

negative battery terminal

manual mode

for engine technical

before

Battery

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

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

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

3. ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

always

wear safety glasses.

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.

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 (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.

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the UVWO output terminals.

National Electrical Code

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

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

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

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

Transporting

■

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. See next page “ basic towing techniques.

clothing or skin

Towing Safety Precautions

, rinse skin or clothing

” for

PAGE 12 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — RULES FOR SAFE OPERATION

Towing Safety Precautions

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Conform to

(DOT) towing generator.

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 suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR) of 6,000 lbs.

■

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

Department of Transportation

Safety Towing Regulations

before

■

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.

■

DOT Requirements include the following:

z z

Emergencies

■

ALWAYS know the location of the nearest

■

ALWAYS know the location of the nearest and

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

fire extinguisher

first aid kit

■

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.

■

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

■

Place 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.

Trailer tires should be inflated to 50 psi cold.

chock blocks

underneath wheel to prevent rolling,

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

always

know the location of the

keep a phone on the job site

and

fire department

. This

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 13

DCA150SSVU — INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — 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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

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.

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 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect the

ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried aminimum of 8 ft. into the ground.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

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-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 15

DCA-150SSVU — TOWING SAFETY PRECAUTIONS

Towing Safety Precautions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 4) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

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

■

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

■

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

■

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

■

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

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

■

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

■

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

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place rolling, while parked.

■

Place prevent tipping, while parked.

■

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

■

Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 3. Generator with Trailer

PAGE 16 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — TRAILER SPECIFICATIONS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Explanation of Chart:

This section is0 to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

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



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions when reading Table 2.

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).

ALWAYS make sure the trailer is in good

operating condition. Check the tires for proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

5. Frame Length - 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.

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 17 and Figure 67 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.

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.

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

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 17

DCA150SSVU — TRAILER SPECIFICATIONS

snoitacificepSreliarT.2elbaT

LEDOM NOITACILPPA LEUF

W01-RLRT ,522WDS

-WLT,052WGS

003

01-RLRT ,01ACD

-ACD,21GLT

FX01-RLRT -GLT,01ACD

,51ACD,21

003-WLT

W522-RLRT ,SREDLEW

SS0007AD

004WLB-RLRT 004-WLBONCIRTCELESBL0072TSAM/W

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

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

W07-RLRT ,06-,54-ACD

X07-RLRT ,06-,54-ACD

FX07-RLRT ,06-,54-ACD

FX001-RLRT 521,001-ACDLAG051CILUARDYH

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002CILUARDYH

FX022-RLRT 022-ACDLAG052CILUARDYH

FX003-RLRT 003-ACDLAG052CILUARDYH

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

LLEC

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

ONEGRUSSBL0007"681"77.BL0002

TPOEGRUSSBL0007"831"66.BL0002

LAG35EGRUSSBL0007"831"66.BL0002

LAG541CILUARDYHSBL00001"681"77.BL0002

EKARB

METSYS

EGRUS

RWVG EMARF

HTGNEL

"451

"421O/W

SBL0007"091"67.BL0002

SBL06111"402"48.BL0005

SBL00041"222"38.BL0005

SBL00081"832"38.BL0005

EMARF

HTDIW

"55

"87(

)LLAT

KCAJ

DNATS

LEEHWTLITLLUF

.BL008

LEEHWTLITLLUF

DAPTALF

PAGE 18 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — TRAILER SPECIFICATIONS

)t'noC(snoitacificepS.2elbaT

LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W01-RLRT SSALCLLAB"2

01-RLRT SSALCLLAB"2

FX01-RLRT SSALCLLAB"2

W522-RLRT SSALCLLAB"2

WLB-RLRT

004

X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

W07-RLRT SSALCLLAB"2

X07-RLRT SSALCLLAB"2

FX07-RLRT SSALCLLAB"2

FX001-RLRT -2ELBATSUJDA

ELBATSUJDA2

SSALCLLAB"2

ELBATSUJDA2

ELBATSUJDA"3

EYE"3TPO6/5

C31-571"05.4X"312X2#0022GUL5FAEL3MOOLERIW4

C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4

B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4

C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

C41-502

)4(SAIB

C41-502

)4(SAIB

C41-502

)4(SAIB

C51-502

)4(SAIB

"5X"41.sbl0053

"5X"41sbl0053

"5X"41.sbl0053

"5.5X"41sbl0053

TALFELOP4

"8/3-2

GUL5FAEL4ELOP4

TALFREBBUR

GUL5FAEL4ELOP4

TALFREBBUR

GUL5FAEL5ELOP4

TALFREBBUR

GUL5FAEL5ELOP4

TALFREBBUR

GUL5FAEL5ELOP4

TALFREBBUR

GUL5FAEL5MOOLERIW4

521/58-RLRT -2ELBATSUJDA

EYE"3TPO6/5

FX051-RLRT EYELLAB"3E61-057

FX022-RLRT EYE"3

ELBATSUJDA

FX003-RLRT EYE"3

ELBATSUJDA

FX004-RLRT EYE"3

ELBATSUJDA

FX006-RLRT LEEHWHT5H5.71R57/512TS

RA008-RLRT LEEHWHT5H5.71R57/512TS

D51R57/522TS

)4(LAIDAR

)4(SAIB

E61R58/532TS

)4(LAIDAR

E61R58/532TS

)6(LAIDAR

E61R58/532TS

)6(LAIDAR

)8(LAIDAR

"6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4

"7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4

"7X"61sbl0007-)2(GUL8XELFQMOOLERIW4

"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4

"7X"61-bl0007-)3(

"7X"61-l00001-)3(

GUL8XELFQMOOLERIW4

GUL8FAEL7MOOLERIW6

GUL8EDIR-RIAMOOLERIW6

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 19

DCA150SSVU — GENERATOR DECALS

The DCA-150SSVU generator is equipped with a number of safety decals. 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.

PAGE 20 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — GENERATOR DECALS

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 21

DCA150SSVU — GENERAL INFORMATION

DCA-150SSVU Familiarization

Generator

The MQ Power Model DCA-150SSVU is a 96 kW (Figure 4) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

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

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel Level Gauge

Engine Speed Switch

Coolant Level Alarm Lamp

Panel Light

Panel Light Switch

Auto ON/OFF Engine Controller

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

Over-Current Relay

Output Terminal Panel

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

Three 250 VAC output receptacles (CS-6369), 50 amps

Three auxiliary circuit breakers, 250V @50 amps

Two 125 VAC output receptacles, (GFCI), 20 amps

Two GFCI circuit breakers, 120V@ 20amps

Five output terminal lugs (3Ø power)

Control Box

The “Control Box” is provided with the following:

3-Pole, 400 amp Main Circuit Breaker

Automatic Voltage Regulator

Current Transformer

Emergency Relay

generator

Open Delta Excitation System

The DCA-150SSVU 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, 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 ot 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-150SSVU is powered by a 4 cycle, water cooled, turbocharged Volvo Model TAD720GE engine is designed to meet 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.

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±.5%. The electronic governor option increases frequency variation to ±0.25%.

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 5) as a guide for selecting proper extension cable size.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

diesel

engine. This

PAGE 22 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA150SSVU — MAJOR COMPONENTS

Figure 4. Major Components

3elbaT

.ONMETINOITPIRCSED

1ylbmessArelffuM

2ylbmessAenignE

3ylbmessAerusolcnE

4ylbmessArotareneG

5ylbmessAlanimreTtuptuO

6ylbmessAknaTleuF

7ylbmessAyrettaB

8ylbmessAlenaPlortnoCrotareneG

stnenopmoCrojaMrotareneG

9ylbmessAlenaPgnitarepOenignE

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 23

Figure 5. Generator Control Panel

DCA-150SSVU — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of the DCA-150SSVU "

1. Main Circuit Breaker – This three-pole, 400 amp main breaker is provided to protect the UVWO output terminals from overload.

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. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

4. Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

5. Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

6. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the output voltage present at the UVWO terminals.

Generator Control Panel

" (Figure 5).

Located behind the generator control panel is the

Control Box

electronic components required to make the genertator function.

The “Control Box” is equipped with the following major components:

Over-Current Relay

Voltage Rectifer

Starter Relay

Engine Controller (Computer Controlled)

Current Transformer

Voltage Selector Switch

NOTE

To restore power to the UWVO output terminals, press the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current flowing from the UWVO output terminals to the load.

In the event of a short circuit or

over current condition, it will automatically trip the main 250 amp breaker.

overcurrent

main

closed

position (ON).

PAGE 24 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

NOTE PAGE

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 25

DCA-150SSVU — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

PAGE 26 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-150SSVU "

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. When starting the generator the oil pressure mar read a little bit higher, but after the engine warms up the oil pressure should return to the green zone.

4. Water Temperature Gauge – During normal operation this gauge be should read between 165

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 or high).

9. Coolant Level Alarm Lamp – Is lit (ON) when the coolant level is lower than the fixed amount and will cause the engine to stop. If the generator is not placed on

level

ground the coolant level switch may

not function correctly.

10. Auto On/Off Engine Controller – 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. Any

major

controller to shutdown the generator.

Engine Operating Panel

fault will cause the

" (Figure 7).

and 203oF.

During engine for 10 seconds before disengaging. If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s " mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the "

Also the engine controller will shutdown the generator 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. Off/Manual/Auto Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure

C. High Coolant Temperature – Indicates the engine

D. Overcrank Shutdown – Indicates the unit has

E. Overspeed Shutdown – Indicates the engine is

F. Engine Running – Indicates that engine is running

cranking cycle

Over Speed Protection

running of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the immediately.

If the generator is to be connected to a building's AC power source via a transfer switch (isolation), place the switch in the generator will monitor the AC line output from the building's power source.

has fallen below 29 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

temperature has exceeded 235°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

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.

running at an unsafe speed. This is considered a fault.

at a safe operating speed.

manual

fault.

, The MPEC will attempt to crankthe

Over Crank Protection

" mode.

position, the generator will start

auto

position. In this position the

major

fault.

major

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 27

DCA-150SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Familiarization

The “

Output Terminal Panel

the following:

Three (3) 240V Output Receptacles, 50 amp

Three (3) Circuit Breakers 240V @50 amps

Two (2) 120V GFCI receptacles, 20 amp

Two (2) GFCI Circuit Breakers 120V@ 20 amps

One 400 Amp Main Circuit Breaker

Five (5) Output Terminal Lugs

” (Figure 8) is provided with

Output Terminal Panel

The located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTE

( Figure 8) shown below is

Terminal legs “O” and “Ground” are considered

bonded grounds

Figure 8. Output Terminal Panel

PAGE 28 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any 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 UVWO terminals.

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 auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the UVWO terminals.

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

Figure 11. Voltage Regulator Control Knob

Removing the Plastic Face Plate (UVWO Terminals)

The UVWO terminal lugs are protected by a plastic face plate cover (Figure 12). Un-lock the locking latch, and lift the terminal cover to gain access to the plastic face plate. Remove the screws securing the face plate to the terminal enclosure, then lift the plastic hinged face plate.

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

After the load wires have been securely attached to the UVWO terminals, reinstall the plastic face plate. Place the

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240 VAC, 50 amp auxiliary twist-lock (CS-

6369) recepacles (Figure 10) provided on the output terminal

panel.These receptacles can voltage selector switch is placed in the

only

be accessed when the

single-phase 240/

terminal cover in the down position and secure the locking latch.

120 position.

Figure 12. Plastic Face Plate (UVWO Terminals)

Figure 10. 240 VAC Twist-Lock

Auxiliary Receptacles

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 29

DCA-150SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the UVWO terminal lugs or the convienience receptacles. (See Figure 13). Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the UVWO output terminals from overload, a 3pole, 175 amp, to switch starting the engine.

main

circuit breaker is provided. Make sure

ALL

circuit breakers to the "OFF" position prior to

Over Current Relay

over current relay

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

Maximum Output

The entire load connected to the UVWO terminal lugs, duplex and auxiliary receptacles must not exceed 132 kw in standby or 120 kw in prime output.

PAGE 30 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — LOAD APPLICATION

Single Phase Load

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

Three Phase Load

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

frequency 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

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 4 below when connecting loads.

spmal

tnempiuqe

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

daoLyBrotcaFrewoP.4elbaT

daoLfOepyTrotcaFrewoP

srotomnoitcudniesahp-elgniS57.0-4.0

tnecsednacni,sretaehcirtcelE

spmalyrucrem,spmaltnecseroulF9.0-4.0

noitacinummoc,secivedcinortcelE

0.1

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 5.

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.

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

Motors and motor-driven equipment draw much greater current for starting than during operation.

slootrewopnommoC8.0

)noitarepOesahPelgniS,zH06(noitceleSelbaC.5elbaT

nitnerruC

serepmA

5.2003006.tf0001.tf006.tf573.tf052

50060021.tf005.tf003.tf002.tf521

5.70090081.tf053.tf002.tf521.tf001

0100210042.tf052.tf051.tf001

5100810063.tf051.tf001.tf56

0200420084.tf521.tf57.tf05

sttaWnIdaoLhtgneLelbaCelbawollAmumixaM

021tA

stloV

042tA

stloV

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 31

eriW01#eriW21#eriW41#eriW61#

.egatlovwolmorftlusernacegamadtnempiuqE:NOITUAC

CAUTION:

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

electrician switch

without this transfer switch.

NOTE

licensed

must install an

isolation (transfer)

. Serious injury or death may result

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.

DCA-150SSVU — GENERATOR OUTPUTS

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 15). To obtain some of

Generator Amperage

Tables 7 and 8 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

the voltages as listed in Table 6 (see below) will require a fine adjustment using the

knob

located on the control panel.

voltage regulator

(VR)

control

Voltage Selector Switch

voltage selector

The

switch (Figure 15) is located above the UVWO Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Figure 15. 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

erepmArotareneG.7elbaT

Ø1—sgnitaR

WkV042V021

0238661 52401802 03522052 53541192 04661333 54781573 05802714

)xaM(06052005

Ø3—sgnitaRerepmArotareneG.8elbaT

WkV802V042V084

02950603 52785783 034010954 5312150135 0493102106 5465163186 0547125167 0680218199

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

NEVER change the position of the

selector switch

while the engine is running.

voltage

ALWAYS place circuit breaker in the open

position before selecting voltage.

elbaliavAsegatloV.6elbaT

esahPeerhT

)elbahctiwS(

esahPelgniS )elbahctiwS(

PAGE 32 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

DCA-150SSVU — GENERATOR OUTPUTS/GAUGE READING

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the UVWO terminals or the 3 twist lock auxilliary receptacles.

Tables 9 and 10 show what amount of current is available at the GFCI receptacles when the UVWO terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

ytilibapaCdaoLelcatpeceRICFG.9elbaT

esUniAVK

)slanimreTOWVU(

V084/042Ø3AMENxelpuDICFG

280

8.77elcatpecerrepspma5

7.37elcatpecerrepspma01

5.96elcatpecerrepspma51

4.56elcatpecerrepspma02

tnerruCdaoLelbaliavA

)SPMA(

V021R02-5

Figure 16. Voltage Selector Switch 240/139V Three Phase

Use this position for

3Ø, 208V/1Ø,120V

Position (for 3Ø, 208V, 120V voltage)

ytilibapaCdaoLelcatpeceRICFG.01elbaT

esUniWK

)9636SC(kcoL-tsiwT

V021/042Ø1AMENxelpuDICFG

060

8.85elcatpecerrepspma5

6.75elcatpecerrepspma01

4.65elcatpecerrepspma51

2.55elcatpecerrepspma02

tnerruCdaoLelbaliavA

)SPMA(

V021R02-5

Figure 17. AC Voltmeter

Change-Over Switch

How to Read the Output Terminal Gauge.

The gauge and selector switch on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the Voltage selector switch is in the 3Ø,240/139V position (See Figure 16), place the

Over Switch

(Figure 17) to the W-U position and the

Ammeter Change-Over Switch

AC Voltmeter Change-

(Figure 19) to the U or W

Figure 19. AC Ammeter

Change-Over Switch

position to read the output on the selected leg.

NOTE

Figure 18 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

Figure 20. AC Ammeter (Amp reading on U lug)

The

ammeter

gauges are only active when the UVWO terminals are in use.

and

voltmeter

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 33

DCA-150SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the position of the 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 UVWO Terminal Output Voltages

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

position as shown in Figure 21.

Voltage Regulator Control Knob

Voltage Selector Switch

and

range

3Ø 208V/1Ø120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 24.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

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

Figure 24. Voltage Selector Switch 3Ø-208V/1Ø-120V Three-Phase Position

Figure 21. Voltage Selector Switch 240/139V

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown in Figure 22.

3. Turn the voltage regulator knob (Figure 26) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 22. UVWO Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

NOTE

Figure 23. Voltage Regulator Knob (139V/240V)

Figure 25. UVWO Terminal Lugs

3Ø-208V/120V Connections

Figure 26. Voltage Regulator Knob (208V)

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø240/139 position and the voltage regulator must be adjusted to 208V.

PAGE 34 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø 480/277 UVWO Terminal Output 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

Three-Phase Position

2. Connect the load wires to the UVWO terminals as shown

in Figure 28.

1Ø 240V/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 30.

2. Connect the load wires to the UVWO terminals as shown in Figure 31.

Figure 30. Voltage Selector Switch 240/120V

Single-Phase Position

Figure 28. UVWO Terminal Lugs

240/139V Three Phase Connections

3. Turn the voltage regulator knob (Figure 29) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 29. Voltage Regulator Knob (139V/240V)

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 35

Figure 31. UVWO Terminal Lugs

1Ø-240V/120V Connections

3. Turn the voltage regulator knob (Figure 32) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 32. Voltage Regulator Knob (1Ø-240/120V)

DCA-150SSVU — PRE-SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 110 amp,

main

circuit breaker is provided to protect the UVW output

Fuel Check

DANGER:DANGER:

DANGER:

DANGER:DANGER:

terminals from overload. In addition two single-pole, 20 amp

GFCI

circuit breakers are provided to protect the GFCI

receptacles from overload. Three 50 amp

load

circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch

ALL

circuit breakers to

the "OFF" position prior to starting the engine.

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

Refilling the Fuel System

notches (Figure 33) on the dipstick. See Table 11 for proper selection of engine oil.

The DCA150SSVU genset may (if equipped with a trailer or skid) have a consists of an

mounted

equipped with a skid type fuel system does not use the internal generator fuel tank.

Fuel spillage on a a

fire

explosion

hot!

engine can cause

. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards.

NEVER!

smoke

around or near the generator.

double fuel tank system

internal

generator fuel tank, and a

(Figure 34), which

trailer

fuel tank. It is also possible the genset can be

skid mounted

fuel tank (Figure 35). The

Figure 33. Engine Oil Dipstick

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 CH-4

API Service Classification CG-4

API Service Classification CF-4

ACEA Specification E3

ACEA Specification E2

of fuel tank system.

ALWAYS fuel.

DO NOT fill the fuel tanks beyond their 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.

liOrotoMdednemmoceR.11elbaT

Use the instructions in this section that applies to your type

Figure 34. Double Fuel Tank System

WARNING:WARNING:

WARNING:

WARNING:WARNING:

77 52(

22-

03-(o0Co)C

egnaRerutarepmeTliOepyT

retaergdnaF

)retaergdnaC

77otFoF

52otC

23-otF

04EASro04-W51EAS

03EASro03-W01EAS

01EASro03-W01EAS

fill the fuel tank with clean and fresh

#2 diesel

ONLY properly trained personel who have

read and understand this section should refill the double fuel tank system. Use

#2 diesel fuel

PAGE 36 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — PRE-SETUP

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Figure 35. Skid Type Fuel Tank System

Refueling Procedure:

DANGER:DANGER:

DANGER:

DANGER:DANGER:

Diesel fuel

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. See Figure 36.

and its vapors are dangerous

ALWAYS! fuel

fill trailer tank

, before filling secondary internal tank.

first

with

#2 diesel

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALWAYS!

before refueling.

Figure 36. Only Fill on Level Ground

2. Trailer Fuel Tank First – The trailer fuel tank is the primary fuel tank and holds a larger capacity of fuel. The fuel in the trailer will be filtered and sent to the engine.

ALWAYS

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 37

place trailer on firm level ground

fill trailer fuel tank (Figure 37) first.

Figure 37. Fuel Tank Filling Order

NOTE

ONLY! use

refueling.

Fuel from the secondary inner tank will eventually drain into the primary trailer tank.

#2 diesel fuel

when

DCA-150SSVU — PRE-SETUP

3. NEVER overfill trailer fuel tank – It is important to read the trailer fuel gauge when filling trailer fuel tank.

DO NOT wait for fuel to rise in filler neck. See Figure 38.

Figure 38. Full Trailer Tank

WARNING:WARNING:

WARNING:

WARNING:WARNING:

DO NOT OVER-FILL fuel system. Leave room for fuel expansion . Fuel expands when heated.

4. Once the trailer tank is full, the can be filled (See Figure 39). Notice how the trailer filler tube level rises when the internal tank is filled.

secondary inner tank

5. Figure 40 below reflects a full fuel system.

Figure 40. Full Fuel System

Fuel from the engine return line will drain into the secondary

internal fuel tank. This fuel will eventually drain into the primary trailer tank in order to return to the engine.

WARNING:WARNING:

WARNING:

WARNING:WARNING:

It is recommended to only fill the internal secondary take to 3/4 full in order to allow for fuel return, fuel expansion, and to avoid spillage. See Figure 41 for fuel expansion.

Figure 39. Filling Secondary Internal Fuel Tank

PAGE 38 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

Figure 41. Fuel Expansion

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

DCA-150SSVU — PRE-SETUP

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. See the engine manual for further details.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator

cap until the unit has completely cooled. The possibility of burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

hot!

coolant exists which can cause severe

NOTE

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

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Volvo Engine Owner's Manual.

Fan Belt Tension

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

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 42) when depressed with the thumb as shown below.

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

battery terminal disconnected.

less than 50%.

yticapaCtnalooC.21elbaT

rotaidaRdnaenignE)sretil62(.laG9.6

knaTevreseR)sretil9.1(strauQ2

Operation Freezing Weather

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

serutarepmeTgnitarepOezeerF-itnA.31elbaT

tnioPgnizeerFtnioPgnilioB

%loV

ezeerF-itnA

C°F°C°F°

0442-21-601222

0573-43-801622

Figure 42. Fan Belt Tension

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER!

the belts or fan while the generator set is running.

place hands near

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 39

DCA-150SSVU — PRE-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.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 43) 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.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the Heat, RUN, or START position. ALWAYS make sure that the ignition switch is in the STOP position when 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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ignition

switch is in either the Pre-

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.

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

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Figure 43. Battery Connections

ALWAYS

terminal FIRST and reconnect negative terminal LAST.

disconnect the negative

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.

DO NOT put water directly on the alternator. Entry of water into the alternator leads an electrolyte corrosion causing an alternator failure.

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

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

PAGE 40 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:WARNING:

WARNING:

WARNING:WARNING:

The engine's exhaust contains harmful emissions.

ventilation when operating

away from nearby personnel.

Before Starting

Generator and Control Panel

ALWAYS have adequate

CAUTION:

. Direct exhaust

NEVER! main, GFCI

the ON (closed) position.

1. Be sure and place the breakers (Figure 44) in the “OFF” position prior to starting the engine.

Figure 44. Main, Aux. and GFCI

Circuit Breakers

2. Connect the load to the

receptacles

connection points can be found on the output terminal panel. To gain access to the UVWO terminals or other power receptacles, unlock the access cover and lift the door.

The UVWO terminals 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.

manually start the engine with the

auailliary

main, G.F.C.I.

UVWO

as shown in Figure 45. These load

circuit breakers in

and

aux.

circuit

terminals or

auxiliary

Figure 45. Load Connections

3. Close all engine enclosure doors (Figure 46).

Figure 46. Engine Enclosure Doors

4. Verify that the coolant alarm lamp is OFF (Figure 47), and the generator is placed on a

Figure 47. Coolant Alarm Lamp

5. Place the voltage selector switch in the desired voltage position (Figure 48).

flat level

surface.

Figure 48. Voltage Selector Switch

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 41

DCA-150SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

6. Set engine speed switch to “LOW ” (Figure 49).

Figure 49. Engine Speed Switch (Low)

7. Place the “MANUAL

Auto-Off/Reset-Manual

”

position to start the engine (Figure 50). Once

switch in the

the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 50. Auto-Off/Reset-Manual Switch

10. The generator's frequency meter (Figure 53) displays the 60 cycle output frequency in HERTZ.

Figure 53. Frequency Meter (Hz)

11. The generator's voltage meter (Figure 54) displays the 120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance,

Figure 54. Voltmeter

8. Once the engine is warm and the engine is running properly,

12. Use the voltage adjustment control knob (Figure 55) to

set the engine speed switch to “HIGH ” (Figure 51).

Figure 51. Engine Speed Switch (High)

13. The ammeter (Figure 56) will indicate zero amps with no

9. Verify that the "Engine Running" status LED on the MPEC

unit (Figure 52) is "ON" (lit) after the engine has been started.

increase or decrease the desired voltage.

Figure 55. Voltage Adjust Control Knob

load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator.

Figure 56. Ammeter (No Load)

Figure 52. Engine Running LED (ON)

PAGE 42 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — GENERATOR START-UP PROCEDURE (MANUAL)

14. The engine oil pressure gauge (Figure 57) will indicate the oil pressure (kg/ cm

of the engine. Under normal

17. Turn the “ON” position (Figure 60).

operating conditions the oil pressure is approximately

Figure 57. Oil Pressure Gauge

15. The coolant temperature gauge (Figure 58) will indicate the coolant temperature. Under normal operating conditions the coolant temperature is between 165 and 215 degrees fahrenheit.

18. Observe the generator's ammeter (Figure 61) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if the load is in use.

main, GFCI

Figure 60. Main, AUX. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers to the

Figure 58. Coolant Temperature Gauge

16. The tachometer (Figure 59) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

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

Figure 59. Engine Tachometer

Figure 61. Ammeter (Load)

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 43

DCA-150SSVU — GENERATOR START-UP PROCEDURE (AUTO MODE)

DANGER:

switch

transfer switch.

. Serious

CAUTION:

NOTE

Before connecting this generator to any building’s electrical

system, a licensed electrician must install an

isolation

injury

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.

(transfer)

death

may result without this

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.

in the event of

CAUTION:

3. Place the Off/Manual/Auto switch (Figure 63) in the “AUTO“ position .

Figure 63. Off/Manual Auto Switch (AUTO)

4. Continue to follow the steps outlined in the “

Start-up”

The

Engine Speed Switch

to the “HIGH” position when running in the

Auto-Start

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

procedure (start at step 9, page 42).

mode. Failing to set the switch

must be set

Manual

WARNING:

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.

1. Perform steps1 through 5 in the (page 41) as outlined in the

2. Set the engine speed switch (Figure 62) to the “HIGH” position.

Figure 62. Engine Speed Switch (High)

Before Starting

Manual Starting Procedure

section

PAGE 44 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — GENERATOR SHUT-DOWN PROCEDURE

Shutdown Procedure - Engine Controller

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 44 to the "OFF position".

2. Place the engine speed switch in the “LOW” position

(Figure 64).

Figure 64. Engine Speed Switch (Low)

3. Let the engine cool by running it for 3-5 minutes with no load applied.

4. Place the Auto-Off/Reset-Manual switch (Figure 65) to the

OFF/Reset

position.

Emergency Shutdown Procedure - Engine Controller

1. To shut-down the engine in the event of an emergency, switch the (Figure 44) circuit breakers to “OFF” position.

2. Place the Auto-Off/Reset-Manual switch (Figure 65) to the “OFF/Reset“ position.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

MAIN, GFCI

and

LOAD

NEVER stop the engine suddenly except

in an emergency. DO NOT use the emergency stop switch a as method of shutting down the generator. This switch is ONLY to be used in the event of an

emergency.

Figure 65. Off/Manual Auto Switch (Off)

5. Verify that the (Figure 52) are "OFF" (not lit).

6. Remove all loads from the generator.

all

status LED on the MPEC display

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 45

DCA-150SSVU — MAINTENANCE

ECNANETNIAM/NOITCEPSNI.41ELBAT

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

ROTARENEG

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

leveLnoitcetorPtnalooCkcehCdnarotaidaRnaelC X

elzzoNnoitcejnIleuFtseT X

tnemelEretliFriAecalpeR X

spmalCdnasesoHllakcehC X

ecnaraelCevlaVkcehC X

elzzoNnoitcejnIkcehC X X

knaTleuFfoedisnInaelC X

smhoM3revOecnatsiseRnoitalusnIerusaeM X

srH01

YLIAD

srH052 srH005 srH0001

1*.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

2*.ylnoemittsrif,sruoH052taretlifleufecalpeR

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.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean the heavy duty paper element with kerosene, or foam element with liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry. For heavy duty paper element, wipe excess kerosene with towel.

Service Daily

If the engine is operating in very 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 conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in

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

the bottom of the tank. Occasionally remove the drain cock and drain the contents. 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.

needs changing. After changing the air element, press the dust indicator button to reset the indicator.

dusty

dry grass

frequently

conditions, a

if these

PAGE 46 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — 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.

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.

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.

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 33.

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 (Table 12 for correct mixture).

Close radiator cap tightly.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

Allow engine to radiator. Flushing the radiator while will damage radiator.

cool

when flushing out

hot!

Replacing Oil Filter

Detach the oil filter by loosening center bolt and remove the element together with the filter body.

Apply a film of oil to the gasket for the cartridge. Install the filter body together with the element and fix

them by tightening the center bolt. 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.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 400 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.

Feed Pump Strainer Cleaning

The strainer is incorporated in the feed pump inlet side joint bolt. Clean the strainer with compressed air and rinse it in the fuel oil.

Generator Storage

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 block so tires do touch the ground or remove tires.

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 47

DCA-150SSVU — MAINTENANCE

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

This generator is 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 66). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 5).

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 heate

hot

climates there is no reason

cold

climates it is always a good

r and i

nternal

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 66. Battery Charger &

Jacket Water Heater Power Connections

PAGE 48 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — TRAILER BRAKES 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 67) 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 67 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 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 67. 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.

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

?dezalggninilekarB.ecalperrohsinrubeR

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

?dedaolrevoreliarT.thgiewtcerroC

?devoorgroderocssmurdekarB.ecalperroenihcaM

?tcerrocerusserperiT.yllauqeseritllaetalfnI

?elxaemasehtnodehctamnuseriT.serithctaM

?dnuor-fo-tuosmurdekarB.ecalpeR

?detacirbulmetsyS.etacirbuL

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

?yltcerrocdetsujda

?diulftcerrocrodiulfekarbhguonE

?nekorbrotneb,esoolstnenopmocekarB.stnenopmocecalpeR

tonrotcerrocnissenkcihtgninilekarB

surge

push

actuator

gnitoohselbuorTekarBciluardyH.51elbaT

dnaseohswenllatsnI

.sgninil

straprebburecalpeR

.diulf4todhtiwllif

” to make

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 49

DCA-150SSVU — 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 68) 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:

as detailed in Table 17.

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.

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.

Figure 68. Major Suspension Components

springs and associated components

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

TABLE 16. TIRE WEAR TROUBLESHOOTING

WEAR PATTERN

Center Wear

Edge Wear

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

CAUSE

Over Inflation.

Under Inflation.

Loss of camber or overloading.

Wheel lockup & tire skidding.

SOLUTION

Adjust pressure to particular load per tire manufacturer.

Adjust pressure to particular load per tire

manufacturer. Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment

and balance tires.

Avoid sudden stops when possible and adjust brakes.

SHACKLE BOLT SPRING EYE BOLT

SHOULDER TYPE SHACKLE BOLT

CAUTION:

ALWAYS

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

wear safety glasses when removing

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY.PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

BOLT ASSEMBLY

stnemeriuqeReuqroTnoisnepsuS.71elbaT

05-XAM03-NIM

PAGE 50 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — 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 69. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 17.

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

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

NEVER

NOTE

gun to tighten wheel lug nuts.

ssaPdnoceS

SBL-TF

use an pneumatic air

ssaPdrihT

SBL-TF

Figure 69. Wheel Lug Nuts Tightening Sequence

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 51

DCA-150SSVU — TRAILER-WIRING DIAGRAM

Figure 70. Trailer/Towing Vehicle Wiring Diagram

PAGE 52 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — GENERATOR WIRING DIAGRAM

Figure 69. Engine Wiring Diagram

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 53

Figure 71. Generator Wiring Diagram

DCA-150SSVU — ENGINE WIRING DIAGRAM (WITH CONTROLLER)

Figure 72. Engine Wiring Diagram (Controller)

PAGE 54 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

NOTE PAGE

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 55

DCA-150SSVU — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

woltalioenigneroleuf

?erutarepmet

?tungniniaterepip

diagnosis based on the Engine Troubleshooting (Table 19). If the problem cannot be remedied, consult our company's business office or service plant.

foytisocsivhgihylevissecxE

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

GNITOOHSELBUORTENIGNE.91ELBAT

.lioenigneroleufdeificepsehtesU

.tunnethgiT

.tratstonseodenignE

?rednilyc

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?gninoitcnuflamretratS .ecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?detcennocsidgniriW .gniriwtcennoC

PAGE 56 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.91ELBAT

noitcejniesooloteudkaelleuF

?tungniniaterepip

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

.htoomstonsinoituloverenignE

?erusserp

?deggolc

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?kcuts

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?desuleufedargwoL .leufdeificepsehtesU

.tunnethgiT

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 57

DCA-150SSVU — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 20) . If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 58 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — TROUBLESHOOTING (ENGINE CONTROLLER)

GNITOOHSELBUORTRELLORTNOCENIGNE.12ELBAT

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

thgilerusserpliowoL

.nosi

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

thgilleveltnaloocwoL

.nosi

tnaloochgiH

.nosithgilerutrepmet

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

.nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenignE.relaedotrefeR

ro)s(thgilUPMfossoL

.no

?ytridpukcipcitengaM .pukcipcitengamnaelC

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 59

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, or <, belong to the same assembly or kit

If more than one of the same

NOTE

reference number is listed, the last one listed indicates newest (or latest) part available.

The contents of this catalog are subject to change without notice

, #, +, %,

PAGE 60 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — SUGGESTED SPARE PARTS

DCA-150SSVU W/VOLVO TAD720GE DIESEL ENGINE 1 TO 3 UNITS

Qty. P/N Description

1 ........0601820671 ..................... AUTOMATIC VOLTAGE REGULATOR

1 ........47530102 ........................KNOB, SELECTOR SWITCH

1 ........0601840073 ..................... RHEOSTAT, VOLTAGE REGULATOR

1 ........0601840121 ..................... KNOB, RHEOSTAT

3 ........978515 ............................V-BELT, ALTERNATOR

3 ........978750 ............................V-BELT, FAN

20 ......V3831236 ........................OIL FILTER

20 ......V3825133 ........................FUEL FILTER

10 ......V20405830 ...................... AIR ELEMENT

1 ........V20405972 ...................... RADIATOR HOSE, UPPER

1 ........V20405956 ...................... RADIATOR HOSE, LOWER

1 ........0602103092 ..................... LAMP, PILOT ALARM

1 ........0601810245 ..................... BULB, PILOT LAMP

1 ........0602123263 ..................... WATER TEMPERATURE UNIT

1 ........0602122272 ..................... OIL PRESSURE UNIT

1 ........0605505070 ..................... FUEL TANK CAP

1 ........M9310000103 ..................ENCLOSURE CAP

1 ........M1483600204 ..................ENCLOSURE CAP CHAIN ASSEMBLY

1 ........0602123261 ..................... WATER TEMPERTURE UNIT

2 ........0601808803 ..................... CIRCUIT BREAKER, QOU120B 20A

3 ........0601808804 ..................... CIRCUIT BREAKER, QOU250B 50A

3 ........V20430640 ...................... FILTER, WATER SEPARATOR

1 ........ECU9988N150V .............. CONTROLLER ECU

Part number on this Suggested Spare

NOTE

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 61

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

NAME PLATE ASSY.

DCA-150SSVU — NAMEPLATE AND DECALS

PAGE 62 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — NAMEPLATE AND DECALS

NAME PLATE 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 M3550001303 DECAL, CONTROL PANEL ......................................................... 1 ............. M35000130

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

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

2-4 M9520100004 DECAL, WARMING ELECTRIC SHOCK HAZARD ......................1 ............. M92010000

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

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

2-7 M9522000204 DECAL, HIGH IDLE SPEED .......................................................1 ............. M92200020

2-8 M3550001203 DECAL, OPERATING PANEL ......................................................1 ............. M35000120

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 M3550000804 DECAL, NOTE .............................................................................1 ............. M35000080

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

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

4-6 M9520100004 DECAL, WARNING ELECTRIC 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

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

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 63

NAME PLATE ASSY. (CONT.)

DCA-150SSVU — NAMEPLATE AND DECALS (CONT.)

PAGE 64 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — NAMEPLATE AND DECALS (CONT.)

NAME PLATE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

BONNET GROUP 0

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

8-2 0600500090 EMBLEM 1 8-2 0021106015 MACHINE SCREW 2 8-3 M3560100903 STRIPE 1 8-4 M3560101003 STRIPE 2 8-5 M3560101604 STRIPE 2 8-6 M3560101304 STRIPE 2 8-7 M3560101203 STRIPE 1 8-8 M3560101403 STRIPE 1 8-9 M3560101504 STRIPE 2 9-1 TBD DECAL,FUELING PROCEDURE 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 65

GENERATOR ASSY.

DCA-150SSVU — GENERATOR ASSY.

PAGE 66 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0110000402 ROTOR ASSEMBLY .................................. 1.......... INCLUDES ITEM W/

1-1

1-2*8131070013 FAN 1 1-3*B131611014 COUPLING DISK 8

1-4*8131015003 BALANCING PLATE .................................. 1 .......... PURCHASE 1-14 AS A SET

1-5*0012112035 HEX. HEAD BOLT 10 1-6*0042612000 SPRING WASHER 10

1-7*8101026013 SET PLATE, RECTIFIER ..........................1 .......... PURCHASE 1-14 AS A SET

1-8*0601821349 RECTIFIER ............................................... 2.......... PT 3610

1-9*0601822601 SURGE ABSORBER ................................. 1 .......... ERZ- M14JK621A

1-10*8001020004 INSULATOR WASHER 1 1-11*8001020504 INSULATOR WASHER 1 1-12*0010110020 HEX. HEAD BOLT 4 1-13*0040010000 SPRING WASHER 4 1-14*0601000209 BALANCING WEIGHT KIT 1

1-15*0076506312 BEARING .................................................. 1 .......... 6312SN34DDUC3

2 C0130000003 STATOR ASSEMBLY .................................1 .......... C0134000304

3 0845041804 GROMMET 2 4 8131315202 END BRACKET 1 5 8101350013 FIELD ASSEMBLY EXCITER 1 6 0012110060 HEX. HEAD BOLT 4 7 0042610000 SPRING WASHER 4 8 0041210000 PLAIN WASHER 4 9 0010112035 HEX. HEAD BOLT 6 10 0040012000 SPRING WASHER 6 11 0041212000 PLAIN WASHER 6 12 8131310104 COVER, BEARING 1 13 8131312204 GASKET, BEARING 1 14 8131331003 COVER, END BRACKET 1 15 0017106012 HEX. HEAD BOLT 10 16 8101333003 COVER, END BRACKET 1 17 0010106030 HEX. HEAD BOLT 2 18 0040006000 SPRING WASHER 2 19 0041206000 PLAIN WASHER 2 20 M3163400503 COUPLING RING 1 21 0010310075 HEX. HEAD BOLT 8 22 0042510000 SPRING WASHER 8

23 0070506306 BEARING .................................................. 1 .......... 6306ZZ

24 0012810030 HEX. HEAD BOLT 12 25 0012810030 HEX. HEAD BOLT 12 26 C0131300004 COVER, FAN 1 27 0600815000 NUT 1 28 060500013 RUBBER SUSPENSION 2 29 0030016000 HEX. NUT 2 29 0040016000 SPRING WASHER 2

FIELD ASSEMBLY 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 67

CONTROL BOX ASSY.

DCA-150SSVU — CONTROL BOX ASSY.

PAGE 68 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3213000502 CONTROL BOX 1

2 0601808821 CIRCUIT BREAKER ..................................1 .......... LAF364001039 3P 400A

3 0021006080 MACHINE SCREW 4

4 0601823863 RELAY UNIT ............................................. 2 .......... MSA9013A

5 0027104016 MACHINE SCREW 4

6 0601820671 AUTOMATIC VOLTAGE REGULATOR........ 1 .......... NTA- 5A- 2DB

7 0027105016 MACHINE SCREW 4

8 0601806127 CURRENT TRANSFORMER ..................... 3 .......... 814- 943 300: 5A

9 0027106016 MACHINE SCREW 6

10 0601820845 OVER CURRENT RELAY .......................... 1 .......... LR2D1308

11 0601820846 OVER CURRENT RELAY .......................... 1 .......... LA7D1064

12 0027104016 MACHINE SCREW 2 13 0207004000 HEX. NUT 2 15 M3213500013 CONTROL BOX COVER 1 16 0016906016 HEX. HEAD BOLT 4

17 M3923100014 SELECTOR SWITCH ................................ 1 .......... VY- 200

17A 47530102 KNOB, SELECTOR SWITCH 1 18 M3213600203 SWITCH BRACKET 1 19 0330000370 EDGING 2 20 0027104010 MACHINE SCREW 4 21 0016906016 HEX. HEAD BOLT 8 22 M3213600304 SWITCH COVER 1 23 0016906016 HEX. HEAD BOLT 4 24 0016906016 HEX. HEAD BOLT 13 24 0040506000 TOOTHED WASHER 1 25 M3223000303 CONTROL PANEL 1

26 0601807641 FREQUENCY METER .............................. 1 .......... FCF- 6 45~65HZ 240V

27 0601808989 AC AMMETER .......................................... 1 .......... ACF- 6 0~300A/600A

28 0601801040 CHANGE- OVER SWITCH, AMMETER ....1 .......... SL- 2AS

29 0601806859 AC VOLTMETER ....................................... 1 .......... SCF- 6 0~600V

30 0601801041 CHANGE- OVER SWITCH, VOLTMETER . 1 .......... SL- 2VS

31 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ....... 1 .......... RA20A2SE102BJ 2W 1K OHM.

32 0601840121 KNOB, RHEOSTAT 1 33 M1223100004 STOPPER 1 34 0027105016 MACHINE SCREW 2 35 0027105016 MACHINE SCREW 4 36 M9220100004 SET SCREW 1 37 0080200007 SNAP RING 1

38 0601823240 RECTIFIER ............................................... 3 .......... DE4503

39 0027104040 MACHINE SCREW 1

40 0601826031 RELAY ....................................................... 1 .......... AHE1231 DC12V

41 0027104016 MACHINE SCREW 2

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 69

CONTROL BOX ASSY. (CONT.)

DCA-150SSVU — CONTROL BOX ASSY. (CONT.)

PAGE 70 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

42 LY2DUS12VDC RELAY ....................................................... 1 .......... REPLACES 0601827656

42 PTF08A RELAY BASE ............................................ 1 .......... REPLACES 0601823109

42 PYCA1 RELAY CLIP .............................................. 2 .......... REPLACES 0601824400

43 LY2DUS12DVC RELAY ....................................................... 2 .......... REPLACES 0601823768

43 PTF08- A RELAY BASE ............................................ 2 .......... REPLACES 0601823109

43 PYCA1 RELAY CLIP .............................................. 4 .......... REPLACES 0601824400

44 0027104020 MACHINE SCREW 6

45 0602202568 SPEED CONTROL UNIT ........................... 1 .......... ESD5 500E

46 0027105016 MACHINE SCREW 4

47 V150053623 SPEED SENSOR ...................................... 1 .......... REPLACES 0602120475

48 0016906020 HEX. HEAD BOLT 1 49 M3246700824 WIRE HARNESS, GENERATOR 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 71

ENGINE & RADIATOR ASSY.

DCA-150SSVU — ENGINE AND RADIATOR ASSY.

PAGE 72 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3923200034 ENGINE & RADIATOR SET ...................... 1 .......... VOLVO TAD720GE

1-1 V20405830 ELEMENT, AIR CLEANER ........................ 1 .......... REPLACES 0602046621

1-2 V3831236 CARTRIDGE, OIL FILTER ........................ 1 .......... REPLACES 0602041277

1-3 V3825133 CARTRIDGE, FUEL FILTER ..................... 1 .......... REPLACES 0602042560

2 M3303200104 ENGINE FOOT 2 3 0010312100 HEX. HEAD BOLT 2 4 0030312000 HEX. NUT 2 5 0042512000 SPRING WASHER 4 6 0605000011 RUBBER SUSPENSION 2 7 0030016000 HEX. NUT 2 8 0040016000 SPRING WASHER 2 9 M3423500004 SEAL BRACKET 1 10 0263202750 SEAL RUBBER 1 11 0016908020 HEX. HEAD BOLT 8 12 0207008000 HEX. NUT 8

13 0602022563 ADAPTER .................................................. 1.......... F80X- S

14 0602022561 90 DEG. ELBOW ....................................... 1.......... 33982-10-10+

15 0603306590 CONNECTOR ............................................ 1 .......... 10WFTX- S

16 0603300285 ROCKNUT ................................................. 1 .......... 10WLN

17 0605511395 VALVE ....................................................... 1 .......... XV500P- 8

18 0603306395 HOSE JOINT ............................................. 1 .......... 30182- 8- 10

19 0602021070 CAP ........................................................... 1.......... 10FNTX- S

20 0269200406 DRAIN HOSE 1 21 M4323500004 ADAPTER 1

22 V969011 PACKING ................................................... 1 .......... REPLACES 0602012340

23 0603306487 STREET ELBOW ...................................... 1 .......... 2102-6-6

24 0605511397 VALVE ....................................................... 1 .......... MV608-6

25 0602022778 HOSE JOINT ............................................. 1 .......... 102-06-06

26 0199100500 DRAIN HOSE 1

27 0605515109 HOSE BAND ............................................. 1 .......... RS-8010

28 0199101600 OVER FLOW HOSE 1

29 V20412270 COOLANT LEVEL SENSOR .....................1 .......... REPLACES 0602211311

30 V969011 PACKING ................................................... 1 .......... REPLACES 0602012340

31 0602150070 ACTUATOR ................................................ 1.......... ADD2255-12

32 0602211070 MOUNTING KIT ........................................ 1 .......... KT-1213B

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 73

DCA-150SSVU — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE & RADIATOR ASSY. (CONT.)

PAGE 74 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE & RADIATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

33 V20412362 RADIATOR 1 34 V20412281 CAP, RADIATOR 1 35 V20417379 UPPER WATER PIPE 1 36 V20405972 UPPER HOSE RADIATOR 1 37 V20405956 LOWER HOSE RADIATOR 1 38 V20412342 LOWER WATER PIPE 1 39 V20412341 LOWER WATER PIPE GASKET 1 40 V947281 BOLT 1 41 V947281 GASKET WATER PIPE SET 1 42 V20405946 FAN 1 43 V20405685 WATER PUMP 1 44 V11700524 GASKET WATER PUMP 1 45 V11700522 O-RING WATER PUMP1 46 V20405689 THERMOSTAT 1 47 V975678 GASKET THERMOSTAT 1 48 V978515 V-BELT, ALTERNATOR 1 49 V978750 V-BELT, FAN 1 50 V20405794 ALTERNATOR 12 VOLT 1 51 V20405828 STARTER 12 VOLT 1 52 V20430640 WATER SEPARATOR FILTER 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 75

DCA-150SSVU — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

PAGE 76 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 ECU9988N150V CONTROLLER, ECU .............................................. 1 ......... REPLACES 0602202545

2 0601831340 SWITCH ................................................................. 1 ......... 7562K4

3 0601831395 ENGINE SPEED SWITCH ..................................... 1 ......... 7302K36

4 0602120096 TACHOMETER ....................................................... 1 ......... 111812

5 0602122097 OIL PRESSURE GAUGE ....................................... 1 ......... 100728

6 0602123094 WATER TEMPERATURE GAUGE .......................... 1 ......... 111930

7 0602121080 CHARGING AMMETER ......................................... 1 ......... 100158

8 0602125090 FUEL GAUGE......................................................... 1 ......... 100176

9 0602103092 ALARM LAMP ........................................................ 1 ......... PL-05

9 0601810245 BULB ...................................................................... 1 ......... E-10 T-10 DC18V

10 0601810141 PANEL LIGHT ......................................................... 1 ......... 98268-00370

11 0601831330 SWITCH, PANEL LIGHT ........................................ 1 ......... 90-001

12 0601802149 FUSE, 10A 1 13 0601806671 FUSE, 15A 1 14 M3357200712 WIRE HARNESS, ENGINE 1 15 M3357200904 WIRE HARNESS, COOLANT LEVEL SENSOR 1 16 V20405778 SENSOR, OIL PRESSURE 1 17 V969011 GASKET, OIL SENSOR 1 18 V20412270 UNIT, OIL LEVEL GUARD 1 19 V20405787 SENSOR, WATER TEMP. 1 20 V20405788 SLEEVE, INSULATING WATER TEMP. 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 77

DCA-150SSVU — OUTPUT TERMINAL PANEL ASSY.

OUTPUT TERMINAL ASSY.

DCA-150 SSVU — OUTPUT TERMINAL ASSY.

PAGE 78 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — OUTPUT TERMINAL PANEL 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 SPRING WASHER 15 6 0041416000 PLAIN WASHER 20 7 0016908035 HEX. HEAD BOLT 5 8 M3238100103 TERMINAL COVER 1 9 M3236100104 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11 0030003000 HEX. NUT 4 11 0041203000 PLAIN WASHER 4 12 0027103010 MACHINE SCREW 4 12 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 .................................. 2 .......... QOU 120B 1P 20A

19 0601808804 CIRCUIT BREAKER .................................. 3 .......... QUO 250B 2P 50A

20 M1260700304 BREAKER FITTING COVER 1 20-1 0222100150 CUSHION RUBBER 1 21 0016906020 HEX.HEAD BOLT 2

22 0601812598 RECEPTACLE ........................................... 2 .......... GF530EM 125V 20AX2

23 0601812538 RECEPTACLE ........................................... 3 .......... CS63 69 250V 50A

24 0027104016 MACHINE SCREW 10 24 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 BLIND PLUG 2 31 0027104016 MACHINE SCREW 4

32 0601815194 TERMINAL ................................................ 1 .......... 601-GP-02

33 0027104016 MACHINE SCREW 2

DCA-150 SSVU — OUTPUT TERMINAL ASSY.

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 79

BATTERY ASSY.

DCA-150SSVU — BATTERY ASSY.

PAGE 80 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — 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 M3346900704 BATTERY CABLE 1 7 M3346900604 BATTERY CABLE 1

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

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

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 81

MUFFLER ASSY.

DCA-150SSVU — MUFFLER ASSY.

PAGE 82 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3330100302 MUFFLER 1 2 0016910025 HEX. HEAD BOLT 4 3 M3333000603 EXHAUST PIPE 1

4 V20405969 GASKET ................................................... 1 .......... REPLACES 0602320197

5 M3333200104 GASKET 1 6 0017110030 HEX. HEAD BOLT 4 7 0017110050 HEX. HEAD BOLT 4 8 M3330400804 COVER 1 9 M3330400903 BRACKET 1 10 0016908020 HEX. HEAD BOLT 4

11 0602326062 U BOLT SET ............................................. 1 .......... 89548K

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 83

FUEL TANK ASSY.

DCA-150SSVU — FUEL TANK ASSY.

PAGE 84 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3363000902 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 V20430638 WATER SEPARATOR ................................ 1 .......... REPLACES 0602042266

13-1 V20430640 ELEMENT ................................................. 1.......... REPLACES 0602042766

13-2 V20430641 SEAL O-RING, FUEL FILTER 1 14 0017110040 HEX. HEAD BOLT 2

15 0602022567 90 DEGREE ELBOW ................................ 2 .......... 8M16X1.5C80X-S

16 0602022980 SWIVEL ..................................................... 2 .......... 30682-8-8

18 0191401300 SUCTION HOSE 1 19 0191401000 SUCTION HOSE 1 20 0191303300 RETURN HOSE 1 21 0605515198 HOSE BAND 4 22 0605515100 HOSE BAND 2

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 85

ENCLOSURE ASSY.

DCA-150SSVU — ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

PAGE 86 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3413001502 BASE 1 2 M141340004 UNDER COVER 1 3 0016904020 HEX. HEAD BOLT 2 4 M3423000902 FRONT FROME 1 4 M3493104913 ACOUSTIC SHEET 1 5 0016910025 HEX. HEAD BOLT 6 6 M3423200304 COVER, FRONT FRAME 1 6 M3493103104 ACOUSTIC SHEET 1 7 0016908020 HEX. HEAD BOLT 16 8 M3433000602 CENTER FRAME 1 8 M3493200304 ACOUSTIC SHEET 1 9 0010114040 HEX. HEAD BOLT 12 9 0030014000 HEX. NUT 12 9 0040014000 SPRING WASHER 24 9 0041214000 PLAIN WASHER 24 10 M3443000412 REAR FRAME 1 10 M3493301504 ACOUSTIC SHEET 1 11 0016910025 HEX. HEAD BOLT 4 11 0040510000 TOOTHED WASHER 1 12 M3443300603 REAR COVER 1 12 M3493302204 ACOUSTIC SHEET 1 13 M3443300503 DUCT, REAR COVER 2 13 M3493301804 ACOUSTIC SHEET 1 14 0207006000 HEX. NUT 12 15 0016908020 HEX. HEAD BOLT 12 16 M3443200213 REAR DOOR 1 17 M3443600104 WINDOW PLATE 1 18 0207306000 HEX. NUT 10 18 0041206000 PLAIN WASHER 10 19 M9113000002 DOOR HANDLE ASSEMBLY 1 20 0021806016 MACHINE SCREW 4 20 0030006000 HEX. NUT 4 21 M9110100204 HINGE 2 21 M9116100004 WASHER 2 22 0016908020 HEX. HEAD BOLT 3 23 M9310000004 BLIND PLUG 2 24 M3463100503 ROOF PANEL 1 24 M3493502203 ACOUSTIC SHEET 1 25 M3463200303 ROOF PANEL 1 25 M3493502103 ACOUSTIC SHEET 1 26 M3463500304 OVER COVER, FRONT FRAME 1 27 0016908020 HEX. HEAD BOLT 39 28 M9310000103 BONNET CAP 1 29 M1483600204 CHAIN ASSEMBLY 2 30 M3453200332 SPLASHER PANEL 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 87

ENCLOSURE ASSY. (CONT.)

DCA-150SSVU — ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

PAGE 88 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

30 M3493405514 ACOUSTIC SHEET 1 31 0016908055 HEX. HEAD BOLT 4 32 0016910025 HEX. HEAD BOLT 2 33 M3453002203 SIDE DOOR 1 33 M3493416704 ACOUSTIC SHEET 1 34 M3453002303 SIDE DOOR 1 34 M3493414404 ACOUSTIC SHEET 1 35 M3453000903 SIDE DOOR 1 35 M3493405204 ACOUSTIC SHEET 1 36 M3453001413 SIDE DOOR 1 36 M3493414204 ACOUSTIC SHEET 1 37 M3453301403 DUCT 1 37 M3493415204 ACOUSTIC SHEET 1 38 M3453301803 DUCT 1 38 M3493416604 ACOUSTIC SHEET 1 39 M3453301703 DUCT 1 39 M3493416104 ACOUSTIC SHEET 1 40 M3453300713 DUCT 1 40 M3493415704 ACOUSTIC SHEET 1 41 0207005000 HEX. NUT 33 42 0016906016 HEX. HEAD BOLT 5 43 M9113000002 DOOR HANDLE ASSEMBLY 4 44 0021806016 MACHINE SCREW 16 44 0030006000 HEX. NUT 16 45 M3453700004 GUTTER 1 46 0016906016 HEX. HEAD BOLT 4 47 M9110100204 HINGE 4 47 M9116100004 WASHER 4 48 M9110100304 HINGE 4 48 M9116100004 WASHER 4 49 0016908020 HEX. HEAD BOLT 9 50 0601850097 STOPPER 8 51 0027208025 MACHINE SCREW 8 52 M9310000004 BLIND PLUG 8 53 0016908020 HEX. HEAD BOLT 1 53 0040508000 TOOTHED WASHER 1

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 89

RUBBER SEALS ASSY.

DCA-150SSVU — RUBBER SEALS ASSY.

PAGE 90 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

DCA-150SSVU — RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901075 SEAL RUBBER 3 2 0229200930 SEAL RUBBER 1 3 0228901120 SEAL RUBBER 2 4 0228901090 SEAL RUBBER 4 5 0228900955 SEAL RUBBER 4 6 0228900520 SEAL RUBBER 2 7 0229201200 SEAL RUBBER 4 8 0229201140 SEAL RUBBER 1 9 0228800680 SEAL RUBBER 1 10 0228801070 SEAL RUBBER 2 11 0228800640 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-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 91

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 Return Mater ial 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

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 condition, 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.

for price 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 manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes 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 written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

PAGE 92 — DCA-150SSVU— OPERATION AND PARTS MANUAL (STD) — REV. #1 (06/03/03)

NOTE PAGE

DCA-150SSVU— OPERATION AND PARTS MANUAL (STD)— REV. #1 (06/03/03) — PAGE 93

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

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

PARTS DEPARTMENT

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

SERVICE DEPARTMENT

800-421-1244 FAX: 310- 537-4259

TECHNICAL ASSISTANCE

800-478-1244 FAX: 310- 631-5032

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: 310- 537-1173

MULTIQUIP INC

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

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

. PARTS DEPARTMENT:

SERVICE DEPARTMENT:

Multiquip DCA150SSVU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual