MULTIQUIP Power WHISPERWATT DCA-100SSJU Parts And Operation Manual

Download

PARTS AND OPERATION MANUAL

MQ POWER

DCA-100SSJU

WHISPERWATT

GENERATOR

(Standard)

PARTS LIST NO. M3870300174

S/N UP TO 7400295-100SSJU

S/N FROM 7400296~100SSJU2

Revision #2 (05/03/01)

MUL TIQUIP INC. PARTS DEPARTMENT:

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

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

SERVICE DEPARTMENT:

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

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

SER VICE DEPARTMENT

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

WARRANTY DEPARTMENT

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

MAIN

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

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

MQ POWER DCA-100SSJU AC GENERATOR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE

Specification and part number are subject to change without notice.

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

PARTS ORDERING PROCEDURES

■■

■ Dealer account number

■■

■ Dealer name and address

■■

■ Shipping address (if different than billing address)

■■

■ Return fax number

■■

■ Applicable model number

■■

■ Quantity, part number and description of each part

■■

■ Specify preferred method of shipment:

■■

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)* Airborne Express*

•

Truck or parcel post

•

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

Earn Extra Discounts when

you order by FAX!

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

Number of line items ordered Additional Discount

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

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

■■

■

UPS Ground Service at no charge for freight

■■

■

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

■■

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

do not count towards the 10+ line items.

Extra Fax Discount

for Domestic USA

Dealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Par ts Depar tment!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

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

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

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

CAUTION:

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

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

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

GENERAL SAFETY

■

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

■

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

■

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

■

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

■

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

■

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

■

The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is

hot

components can cause serious

restricted. If the air flow is restricted it will cause serious damage to the

generator or engine and may cause injury to people. The generator engine gives off DEADLY

carbon monoxide gas.

CAUTION

■

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

■

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

■

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

■

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

■

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

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

■

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

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

■

NEVER operate the generator in an

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

causing severe

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

bodily harm or even

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

RULES FOR SAFE OPERATION

CAUTION

■

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

CAUTION

Radiator

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

DO NOT touch or open any of the below

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

■

Backfeed to a utility system can cause electrocution and.or property damage. Do not connect to any building's electrical system except through an approved device or after building main switch is opened.

CAUTION

■

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

2. Coolant Drain Plug - Removing the coolant drain plug

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

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

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

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

RULES FOR SAFE OPERATION

■

Battery

CAUTION

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

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

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

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

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

■

Always service air cleaner frequently to prevent carburetor malfunction.

■

Always disconnect the battery before performing service on the generator .

■

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

■

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

■

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

■

DO NOT allow unauthorized people to operate this equipment.

■

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

■

Refer to the engine technical questions or information.

Loading and Unloading (Crane)

John Deere Engine Owner's Manual

for

■

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

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

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

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

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

clothing or skin

, rinse skin or clothing

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

■

Always drain fuel prior to lifting.

■

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

■

NEVER lift the machine while the engine is running.

■

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

■

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

■

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

■

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

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

RULES FOR SAFE OPERATION

Transporting

■

Always shutdo wn engine before transporting.

■

Tighten fuel tank cap securely.

■

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

■

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

■

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

Emergencies

■

Always know the location of the nearest and

first aid kit

Also know the phone numbers of the nearest

doctor

and

. Know the location of the nearest telephone.

fire department

fire extinguisher

ambulance

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

■

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

■

Keep the machinery in proper running condition.

■

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

■

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

■

DO NOT use plastic containers to dispose of hazardous waste.

■

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

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

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

Towing Safety Precautions

CAUTION :

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

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

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

■

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

■

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

■

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

■

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

■

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

■

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

■

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

■

Place rolling, while parked.

■

Place prevent tipping, while parked.

■

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

■

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

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when tr ansporting.

■

DO NOT transport generator with fuel in tank.

chocked blocks

support blocks

underneath wheel to prevent

underneath the trailer’s bumper to

Figure 1. Generator with Trailer

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

DCA-100SSJU — TRAILER-SAFETY GUIDELINES

CAUTION:

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

Explanation of Chart:

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

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

Brakes

Tires

Lug Nut T orquing

Suspension

Electrical

Brake Troubleshooting T ables

Use the following definitions while reading Table 1.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

DCA-100SSJU — TRAILER-SPECIFICATIONS

snoitacificepS.1elbaT

LEDOM NOITACILPPA LEUF

LLEC

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

X01-RLRT ,51ACD,21-GLT

FX01-RLRT ,51ACD,21-GLT

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

004-WLB 004-WLBONCIRTCELESBL0072"451TSAM/W

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

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

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

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

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

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

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

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

521/58-RLRT ,001,58-ACD

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

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

FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

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

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

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

003-WLT

521

ONONSBL0091"69"05.BL008

LAG15ONSBL0091"69"05.BL008

LAG541CILUARDYHSBL00001"681"77.BL0002

EKARB

METSYS

RWVG EMARF

HTGNEL

"421O/W

HTDIW

"55

)LLAT"87(

EMARF

KCAJ

DNATS

LEEHWTLITLLUF

.BL008

LEEHWTLITLLUF

DAPTALF

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

DCA-100SSJU — TRAILER-SPECIFICATIONS

)t'noC(snoitacificepS.1elbaT

LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W51-01-RLRT SSALCLLAB"2

ELBATSUJDA2

X01-RLRT SSALCLLAB"2

ELBATSUJDA2

FX01-RLRT SSALCLLAB"2

ELBATSUJDA2

W522-RLRT SSALCLLAB"2

ELBATSUJDA2

004WLB SSALCLLAB"2

ELBATSUJDA2

FX51-RLRT SSALCLLAB"2CRL31-87B"05.4X"31"2/1-2#0053GUL5FAEL4REBBURELOP4

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

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

W07-RLRT SSALCLLAB"2

ELBATSUJDA"3

X07-RLRT SSALCLLAB"2

ELBATSUJDA"3

FX07-RLRT SSALCLLAB"2

ELBATSUJDA"3

FX001-RLRT 6/5-2ELBATSUJDA

EYE"3TPO

521/58-RLRT 6/5-2ELBATSUJDA

EYE"3TPO

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

C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4

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

B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4

C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

"8/3-2

C41-502

)4(SAIB

C41-502

)4(SAIB

C41-502

)4(SAIB

C51-502

)4(SAIB

D51R57/522TS

)4(LAIDAR

)4(SAIB

E61R58/532TS

)4(LAIDAR

E61R58/532TS

)6(LAIDAR

E61R58/532TS

)6(LAIDAR

)8(LAIDAR

"5X"41.sbl0053

"5X"41sbl0053

"5X"41.sbl0053

"5.5X"41sbl0053

"6x"41sbl0006-)2(GUL6FAEL7MOOLERIW4

"7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4

"7X"61sbl0007-)2(GUL8XELFQMOOLERIW4

"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4

"7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4

"7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6

"7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6

GUL5FAEL4REBBURELOP4

GUL5FAEL5REBBURELOP4

GUL5FAEL5MOOLERIW4

TALFELOP4

TALF

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

DCA-100SSJU — TRAILER BRAKING SYSTEM

Brakes

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

Electric Brakes

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

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

An electric brake system can be manually adjusted to

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

An electric brake system can be modulated to provide

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

An electric brake system has very little lag time between

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

An electric brake system can provide an independent

emergency brake system.

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

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

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

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

Electric Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

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

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

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

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

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

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

DCA-100SSJU — TRAILER BRAKING SYSTEM

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

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

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

blockage.

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

Figure 3. Hydraulic Brake Components

DCA-100SSJU — TRAILER TIRES & SUSPENSION

Tires/Wheels/Lug Nuts

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

CAUTION:

DO NOT attempt to repair or modify a wheel. DO NOT install an inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the

inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Suspension

The leaf suspension springs and associated components

Tire Wear/Inflation

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

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

CAUTION:

NOTE

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

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

Figure 4. Suspension Components

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-100SSJU — TRAILER TIRES & SUSPENSION

stnemeriuqeReuqroTnoisnepsuS.3elbaT

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FI T ONLY. PARTS MUST ROTATE FREELY.

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAI N NUT

-BOLT ASSEMBLY.

05-XAM03-NIM

Lug Nut T or que Requirements

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

1. Star t all wheel lug nuts by hand.

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

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

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

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

stnemeriuqeReuqroTeriT.4elbaT

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 5. Lug Nut Tightening Sequence

NOTE

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

DCA-100SSJU — TRAILER WIRING DIAGRAMS

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

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

YMPTOM

DCA-100SSJU — TRAILER-BRAKE TROUBLESHOOTING

gnitoohselbuorTekarBcirtcelE.5elbaT

OSSIBLECAUSE

OLUTI ON

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

ANY SHORT CIRCUIT S

FAULTY CONTROLLER

ANY LOOSE CONNECTIONS

IS THE GROUND WIRE SECURE

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

IS THE CONNECTIONS CORRODED

IS THE BRAKE DRUMS SCORED OR GROOVED

IS THE BRAKES SYNCHRONIZED

LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE,BENT OR BROKEN

IS THE BRAKE DRUMS OUT-OF-ROUND

NOISY BRAKES IS THE SYSTEM LUBRICATED

IS THE BRAKE COMPONENTS CORRECT

DRAGGING BRAKES IS THE BEARI NGS OF THE WHEEL ADJUSTED

FIND AND CORRECT

TEST AND CORRECT

FIND AND REPAIR

FIND AND SECURE

CLEAN OR REPLACE

CLEAN AND CORRECT CAUSE OF

CORROSION

MACHINE OR REPL ACE

CORRECT.(SEE PG 8 FOR

SYNCHRONIZ ING

REPLACE COMPONENTS

REPLACE

LUBRICATE

REPLACE AND CORRECT

ADJUST

)

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

DCA-100SSJU — TRAILER-BRAKE TROUBLESHOOTING

gnitoohselbuorTekarBciluardyH.6elbaT

motpmyS esuaCelbissoP noituloS

NO BRAKES IS THE BRAKE LINE BROKEN OR KINKED

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

IS THE TRAILER OVERLOADED

IS THE BRAKE DRUMS SCORED OR GROOVED

IS THE TIRE PRESSURE CORRECT

IS THE TIRES UNMATCHED ON THE SAME AXLE

LOCKING BRAKES IS THE BRAKE COMPONENTS LOOSE,BENT OR BROKEN

IS THE BRAKE DRUMS OUT-OF-ROUND

NOISY BRAKES IS THE SYSTEM LUBRICATED

IS THE BRAKE COMPONENTS CORRECT

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

POSITION

IS THERE ENOUGH BRAKE FLUID OR CORRECT FLUID

? ? ?

REPAIR OR REPLACE

REBURNISH OR REPLACE

CORRECT WEIGHT

MACHINE OR REPLACE

INFLATE ALL TIRES EQUALLY

MATCH TIRES

REPLACE COMPONENTS

REPLACE

LUBRICATE

REPLACE AND CORRECT

INSTALL NEW SHOES AND LININGS

REPLACE RUBBER PARTS

FILL WITH DOT

FLUID

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

DCA-100SSJU — GENERAT OR DECALS

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

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

DCA-100SSJU — GENERAT OR DECALS

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

DCA-100SSJU — SPECIFICATIONS

ledoMUJSS001-ACD

epyTgniraebelgnisfoorppird,detalitnevfles,dleifgnivloveR

noitcennoCerutamrAgaZgiZ/lartueNhtiwratS

esahp3-egatloVelbahctiwsV084,044,614,042,022,802

esahpelgnis-egatloVelbahctiwsV772,452,042,931,721,021

tuptuOybdnatS)WK88(AVK011

tuptuOemirP)WK08(AVK001

ycneuqerFzH06

deepSmpr0081

snoitacificepS.7elbaT

snoitacificepSrotareneG

rotcaFrewoP8.0

lluF)A(BdleveLdnuoS

teef32tadaoL

noitalusnIFssalC

ledoM051FT8606EREEDNHOJ

epyTdegrahc-obrut,noitcejnitcerid,delooc-retaw,elcyC4

srednilyCfo.oNsrednilyc6

ekortSxeroB)mm721xmm601(

tuptuOdetaRmpr0081/PH921

tnemecalpsiD)cc4276(.ni.uc014

gnitratScirtcelE

yticapaCtnalooC)sretil93(.lag3.01

yticapaCliOebuL)sretil71(.lag5.4

snoitacificepSenignE

noitpmusnoCleuF

yrettaB1xHA051-V21

leuFleuFleseiD2#

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

tarh/)L1.52(lag6.6 daollluf tarh/)L0.91(lag0.5 daol4/3

tarh/)L3.31(lag5.3 daol2/1 tarh/)L0.8(lag1.2 daol4/1

DCA-100SSJU — GENERAL INFORMA TION

DCA-100SSJU F AMILIARIZATION Generator

The MQ Po wer Model DCA-100SSJU is a 80 kW that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

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

Tachometer

Water T emperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel level gauge

Engine Speed Switch

Pre-Heat Button

Emergency Stop Button

Battery Switch

Panel Light

Panel Light Switch

Auto Start/Stop Controller

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

V oltmeter Change-Ov er Switch

Pilot Lamp

generator

Open Delta Excitation System

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

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

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

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

Engine

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

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

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

Open-Delta

" excitation system. The open delta

Automatic V oltage Regulator

fixed ceiling

(A VR) is supplied

" and responds

diesel

engine.

Output T erminal Panel

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

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 250 amps

Over-Current Relay

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

Mechanical Governor System

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

DCA-100SSJU — MAJOR COMPONENTS

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 25

Figure 6. Major Components

DCA-100SSJU — DIMENSIONS (T OP, SIDE AND FRONT)

PAGE 26 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 7. Dimensions

NOTE PA GE

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 27

DCA-100SSJU — CONTROL PANEL

PAGE 28 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 8. Control Panel

DCA-100SSJU — CONTROL PANEL

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

1. Main Circuit Breaker – This three-pole, 250 amp main breaker is provided to protect the UNV voltage output terminals from overload.

2. AC Ammeter – Indicates the amount of current the load is drawing from the generator .

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.

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 manual adjustment of the generator’s output voltage.

Control Panel

" (Figure 8).

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

7. AC Voltmeter – Indicates the single phase output voltage present at the UNV terminals.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 29

DCA-100SSJU — ENGINE OPERATING PANEL (WITH KEY)

PAGE 30 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 9. Engine Operating Panel

DCA-100SSJU — ENGINE OPERATING PANEL (WITH KEY)

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

1. Panel light - Normally used in dark places or at night. When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

2. Panel light s witch- When activated, will turn on control panel light.

3. Oil Pressure Gauge – Normal operation should be about 25 psi. When starting the generator the oil pressure may read a bit higher, but after the engine warms up the oil pressure should return to normal.

4. Water T emperature 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.

Engine Operating Panel

" (Figure 9).

F to 215oF.

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 Throttle Lever- This le ver will change the speed of the engine from high to low.

9. Pre-Heat Button – Press hold this button to start the engine in cold conditions.

10. Starter Switch with Key – This switch has three different positions: Stop-Turn the key to stop the engine. Start-Turn the key to this position to start the engine. Release the key once the engine has started and it will automatically return to the operating position.

11. Oil Pressure Indicator - This indicator lets the operator know the oil pressure is dangerously high or low and will shut down the engine.

12. Water Temperature Indicator - This indicator lets the operator know the water temperature is dangerously high and will shut down the engine.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 31

DCA-100SSJU — ENGINE OPERATING PANEL (WITH MPEC)

PAGE 32 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 10. Engine Operating Panel

DCA-100SSJU — ENGINE OPERATING PANEL (WITH MPEC)

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

Engine Operating Panel

" (Figure

10).

1. Panel light - Normally used in dark places or at night. When activated, panel will luminate. When the generator is not in use, turn the panel light switch to the ‘OFF’ position.

been detected the MPEC will evaluate the fault and all major faults will shutdown the generator. During

cranking cycle

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

2. Panel light s witch- When activated, will turn on control

engine by initializing the "Over Speed Protection" mode.

panel light.

Also the MPEC 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 MPEC module.

4. Water T emperature 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.

F to 215oF.

A. Off/Manual/Auto Switch – This switch controls the

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

, The MPEC will attempt to crank the

manual

position, the generator will start

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.

B. Low Oil Pressure – Indicates the engine pressure

8. Engine speed Handle- This handle will change the

speed of the engine from high to low.

9. Pre-Heat Button – Press hold this button

C. High Coolant Temperature – Indicates the engine

(Figure 11) until the preheat lamp is lit (ON).

Figure 11. Preheat Button

D. Overcrank Shutdown – Indicates the unit has

10. MPEC – Microprocessor Engine Control Module –

(MPEC) has a vertical row of status LED's (Figure 11), that

E. Overspeed Shutdown – Indicates the engine is running

when lit, indicate that an engine malfunction (fault), has been detected. When a fault has

Figure 12. MPEC

F. Engine Running – Indicates that engine is running

If the generator is to be connected to a building's AC power source via a transfer switch (isolation), place the switch in the

auto

position. In this position the generator will monitor the AC line output from the building's power source.

has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

major

fault.

temperature has exceeded 215°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

fault.

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is preset at 3 cycles with a 10 second duration. This is considered a

at an unsafe speed. This is considered a

major

fault.

at a safe operating speed.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 33

DCA-100SSJU — OUTPUT TERMINAL P ANEL OVER VIEW

OUTPUT TERMINAL FAMILIARIZATION

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

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Connecting Load

Loads can be connected to the generator by the UNV Lugs or the convenience receptacles. (See figure 15). Make sure to read the operation manual before attempting to connect a load to the generator.

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 250 amps

Over-Current Relay

Output T erminal Panel

The Output Control Panel (See Figure 16) is located on the right hand side (left from control panel) of the generator. The UNV lugs are protected by a face plate cover that can be secured in the close position by a pad lock. (See Figure

13).

Circuit Breakers

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

main

circuit breaker is provided to protect the UNV output

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 have also been provided to protect the load side of the generator from overload. Make sure to switch breakers to the "OFF" position prior to starting the engine.

FIGURE 15. Connecting Load

load

circuit breakers

ALL

circuit

FIGURE 13. Output Terminal Cover

120 V olt Receptacle

Two GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle

Maximum Output

The entire load connected to the UNV Lugs, all four slots in the duplex receptacles, and the must not exceed 88 kW in standby or 80 kW in prime output.

is provided on the output terminal. This receptacle can be used anytime the generator is in operation. The receptacle is controlled by the circuit breaker located on the control panel.

Twist Lock Dual V olta ge Receptac les - To use these receptacles, place the voltage selector switch in the single

Pressing the reset button resets the receptacle after being tripped. Pressing the "Test Button" (See Figure 14) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.

FIGURE 14. GFCI Test Button

PAGE 34 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

phase 240/120 voltage position and adjust the output voltage to 240 volts with the voltage regulator on the Control Panel. Place the voltmeter change-over switch to the U-W position and the ammeter change-over switch to the U or W to read the output.

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

FIGURE 16. Output Terminal Panel

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 35

NOTE

Legs O and Ground are considered Bonded Grounds.

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

Output T erminal Panel Available V olta ges

A wide range of voltages are available to supply load to many different applications. Voltages may be selected by using the voltage selector switch and how you hookup

Maximum Amps

The following table show the maximum amps the entire generator can provide. Do not exceed the maximum amps listed. (See Table 9 below.)

your hard wire connection to the generator. To obtain some of the voltages listed, fine adjustment with the Voltage Regulator on the control panel is necessary. See the table below (Table 8) for a list of available voltages the generator is able to supply.

segatloVelbaliavA.8elbaT

LEDOMUJSS001ACD

EGATLOVESAHP3

)ELBAHCTIWS(

ESAHPELGNIS

)ELBAHCTIWS(

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

Voltage Selector Switch

The voltage selector switch is located above the UVWO Hard Wire Hookup Panel. It has been pro vided for ease of voltage selection.

CA UTION :

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Receptacle Use

When the UVWO terminals are providing power , the receptacle power available decrease. Do not exceed receptacle power av ailable listed on Table 10.

:ledoMUJSS001ACD

detaR

egatloV

esahPelgniS

tloV021

esahPelgniS

tloV042

esahPeerhT

tloV042

esahPeerhT

tloV084

spmAmumixaM.9elbaT

spmAmumixaM

)eriw4(spma2.222

)eriw4(spma1.111

spma142

spma021

Voltage Selector Switch Locking Button

The voltage selector switch has a locking button to protect the generator and generator load from being switched while the engine is running. To lock the Vo ltage Selector Switch, press in the red button located on the Voltage Selector Switch, and use a pad lock to hold it into this position. (See figure 17, page 37)

Over Current Relay

An over current relay is connected to the circuit breaker. In an over current situation, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

PAGE 36 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

esUelcatpeceR.01elbaT

elcatpeceR

esUnirewoP

rewoP

elbaliavA

V021/042

V084/042

esahP-3

AVKWKWK

0017.750

8.595.652.1

7.193.554.2

5.781.456.3

4.389.258.4

esahPelgniS

tsiwTro

9636SCkcoL

xelpuD

AMEN

V021R02-5

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

How to read the output terminal gauges.

The gauges and knobs on the control panel DO NOT effect the generator output in any f ashion. They are there to simply help the operator observe how much power is being supplied produced at the UVWO legs.

When the Voltage selector switch is in the 240/120V position (see figure 17), place the AC Voltmeter Changeover switch to the W-U position and the AC ammeter Change -over Switch to the U or W position to read the output on the selected leg.

FIGURE 20. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

FIGURE 21. AC Ammeter

(Amp reading on U lug)

FIGURE 17. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 18. AC Voltmeter

Change-over switch

(Reading the W-U leg on

the output terminal panel)

FIGURE 19. AC Voltmeter

Guage

(Volt reading on W-U Lug)

NOTE

When using plural single phase voltages, make sure to balance the load on each of the single phase legs.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 37

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

240/120V Hard Wire Hookup

The output terminal panel, when suppling single phase 120 volts, will provide three legs available with 222.2 amps each on three different circuits. (See Figure 23 below .) The voltage selector switch must be set at the single phase 240/120V position. (See figure 22 below.)

The output terminal panel, when suppling single phase 240 volts, will provide one leg only with 111.1 amps available. (See Figure 23 below .) The voltage selector s witch must be set at the single phase 240/120V position. (See figure 22 below.)

480/240V Hard Wire Hookup

The output terminal panel, when suppling three phase 240 volts, will provide one circuit available at 241 amps with any two wires plus the ground. (See Figure 25 below .) The v oltage selector switch must be set at the three phase 480/277V position. (See figure 24 below.)

The output terminal panel, when suppling 3 phase 480 volts, will provide one circuit available at 120 amps available with all three wires plus ground. (See Figure 25 below.) The voltage selector switch must be set at the three phase 480/ 277V position. (See figure 24 below.)

FIGURE 22. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 23. Hard Wire Hookup at 240/120V Position

FIGURE 24. Voltage Selector Switch 480/277V Three Phase

Position

FIGURE 25. Hard Wire Hookup at 480/240V Position

PAGE 38 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

Voltage Selector Switch- 3 Phase 480/277V Position

The following are additional voltages available when the voltage selector switch is in the 3 phase 480/277V position. (See figure 26 belo w.)

Single Phase: 480V, 440V, or 416 Volt

The following connection, with the voltage selector switch locked into the 3 phase 480/277V position (See Figure 26), can offer SINGLE PHASE power at 480V, 440V, or 416V. After hooking up the hard wires to the lugs as shown in figure 29 below, 480V will be the voltage with the Voltage Regulator Knob turned toward maximum. 440 volt will be reached when the Voltage Regulator Knob is turned down, and 416 volt when the Voltage Regulator Knob is toward the lowest setting (See Figure 27).

FIGURE 27. Voltage

Selector Switch 270/120V

Single Phase Position

FIGURE 26. Voltage Selector Switch 480/277V Single Phase

Position

FIGURE 29. Hard Wire Hookup for Single Phase 480V, 440V,

or 416V

Single Phase: 277V, 254V, or 240V

3 Phase, 480V, 440V, or 416 Volt

The following connection, with the voltage selector switch locked into the 3 phase 480/277V position (See Figure 26), can offer THREE PHASE power at 480V, 440V, or 416V. After hooking up the hard wires to the lugs as shown in figure 28 below, 480V will be the voltage with the Voltage Regulator Knob turned toward maximum. 440 volt will be reached when the Voltage Regulator Knob is turned down, and 416 volt when the Voltage Regulator Knob is toward

The following connection, with the voltage selector switch locked into the 3 phase 480/277V position (See Figure 26), can offer SINGLE PHASE power at 277V, 254V, or 240V. After hooking up the hard wires to the lugs as shown in figure 30 below, 277V will be the voltage with the Voltage Regulator Knob turned toward maximum. 254 volt will be reached when the Voltage Regulator Knob is turned down, and 240 volt when the Voltage Regulator Knob is toward the lowest setting (See Figure 27).

the lowest setting (See Figure 27).

FIGURE 28. Hard Wire Hook-up for Three Phase 480V, 440V,

or 416V

FIGURE 30. Hard Wire Hookup for Single Phase 277V, 254V,

or 240V

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 39

DCA-100SSJU — OUTPUT TERMINAL PANEL O VER VIEW

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the voltage selector switch is in the 3 phase 240/139V position. (See Figure 31 belo w.)

Single Phase: 240V, 220V, or 208 Volt

The following connection, with the voltage selector switch locked into the 3 phase 240/139V position (See Figure 31), can offer SINGLE PHASE power at 240V, 220V, or 208V. After hooking up the hard wires to the lugs as shown in figure 34 below, 240V will be the voltage with the Voltage Regulator Knob turned toward maximum. 220 volt will be reached when the Voltage Regulator Knob is turned down, and 208 volt when the Voltage Regulator Knob is toward the lowest setting (See Figure 32).

FIGURE 32. Voltage

Regulator Knob located

on the control panel

FIGURE 31. Voltage Selector Switch 240/139V Three Phase

Position

FIGURE 34. Hard Wire Hookup for Single Phase 240V, 220V,

or 208V

3 Phase, 240V, 220V, or 208 Volt

The following connection, with the voltage selector switch locked into the 3 phase 240/139V position (See Figure 31), can offer THREE PHASE power at 270V, 220V, or 208V. After hooking up the hard wires to the lugs as shown in figure 33 below, 240V will be the voltage with the Voltage Regulator Knob turned toward maximum. 220 volt will be reached when the Voltage Regulator Knob is turned down, and 208 volt when the Voltage Regulator Knob is toward the lowest setting (See Figure 32).

FIGURE 33. Hard Wire Hookup for Three Phase 240V, 220V,

or 208V

Single Phase: 139V, 127V, or 120V

The following connection, with the voltage selector switch locked into the 3 phase 240/139V position (See Figure 31), can offer SINGLE PHASE power at 139V, 127V, or 120V. After hooking up the hard wires to the lugs as shown in figure 35 below, 139V will be the voltage with the Voltage Regulator Knob turned toward maximum. 127 volt will be reached when the Voltage Regulator Knob is turned down, and 120 volt when the Voltage Regulator Knob is toward the lowest setting (See Figure 32).

FIGURE 35. Hard Wire Hookup for Single Phase 139V, 127V,

or 120V

PAGE 40 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — OUTPUT TERMINAL P ANEL OVER VIEW

Voltage Selector Switch- Single Phase 240/120V Position

The following are additional voltages available when the voltage selector switch is in the single phase 240/120V position. (See Figure 36 below)

Single Phase: 120 Volt

The following connection, with the voltage selector switch locked into the single phase 240/120V position (See Figure 36), will offer SINGLE PHASE power at 120V. After hooking up the hard wires to the lugs as shown in figure 39 below, use the Voltage Regulator Knob to fine tune to 120V. (See Figure 37).

FIGURE 37. Voltage

Regulator Knob located

on the control panel

FIGURE 36. Voltage Selector Switch 240/120V Single Phase

Position

FIGURE 39. Hard Wire Hookup for Single Phase, 120 volt

Single Phase, 240 Volt

The following connection, with the voltage selector switch locked into the single phase 240/120V position (See Figure 36), will offer SINGLE PHASE power at 240V. After hooking up the hard wires to the lugs as shown in figure 38 below, use the Voltage Regulator Knob to fine tune to 240V. (See Figure 37)

FIGURE 38. Hard Wire Hookup for Single Phase 240 volt

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 41

DCA-100SSJU — INST ALLA TION

Outdoor Installation

Install the generator in a location where it will not be exposed to rain or sunshine. Make sure the generator is on secure level ground so it cannot slide or shift around. Also install the generator so 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 the engine and alternator parts.

CAUTION :

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

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.

CAUTION

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 14) 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 ar ticle 250-52(c) specifies that the earth ground

rod should be buried a minimum of 8 ft. into the ground.

An electric shock may happen when vibrators are used. Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock.

PAGE 42 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

NOTE

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

DCA-100SSJU — INST ALLA TION

Figure 40. Typical Generator Grounding Application

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 43

DCA-100SSJU — PRE-SETUP

General Inspection Prior to Operation

The DCA-100SSJU generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

Extension Cable

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 Cab le Selection Guide (Table 11 ) as a guide for selecting proper cable size.

Circuit Breakers

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

main

circuit breaker is provided to protect the UNV output

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

GFCI

load

circuit breakers

ALL

circuit

NOTE

ALWAYS consult with a licensed

electrician for correct extension cord wire size.

)noitarepOesahPelgniS,zH06(noitceleSelbaC.11elbaT

sttaWnIdaoLhtgneLelbaCelbawollAmumixaM

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

021tA

stloV

042tA

stloV

eriW01#eriW21#eriW41#eriW61#

.egatlovwolmorftlusernacegamadtnempiuqE:NOITUAC

PAGE 44 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, but without being screw into the filler hole, verify that the oil level is maintained between the two notches (Figure 41) on the dipstick. See Table 10 for proper selection of engine oil.

Fuel

Fill the fuel tank with clean and fresh fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 23, Specification Table 7.

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.

CAUTION

Coolant

diesel fuel.

DO NOT

Never fill the fuel tank while the engine is running or in the dark. Diesel spillage on a hot engine can cause a fire or explosion. If diesel spillage occurs, wipe up the spilled diesel completely to prevent fire hazards.

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

Figure 41. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean and viscous. 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 John Deere Engine Owner's

Manual.

egnaRerutarepmeTliOepyT

F°32~F°401

)C°5-~C°04(

F°5~F°32

)C°51-~C°5-(

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.

liOrotoMdednemmoceR.21elbaT

04-W51EAS

03-W5EAS

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 45

)°51-(C°5woleB03-W0EASRO03EAS

DCA-100SSJU — PRE-SETUP

CAUTION :

When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 13 for engine, radiator , and reserve tank coolant capacities. Make sure the coolant level in the reserve tank is always between the "H" and the "L" markings.

yticapaCtnalooC.31elbaT

rotaidaRdnaenignE)sretiL93(.laG3.01

knaTevreseR)sretiL9.1(strauQ2

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 14) has been added.

Cleaning the Radiator

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

Air Cleaner

Periodic cleaning/replacement is necessar y. Inspect it in accordance with the John Deere 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 John

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 7 to 10 mm (Figure 42) when depressed with the thumb as shown below.

tnioPgnizeerFtnioPgnilioB

%loV

ezeerF-itnA

C° F° C° F°

0442-21-601222

0573-43-801622

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Figure 42. Fan Belt Tension

CAUTION

serutarepmeTgnitarepOezeerF-itnA.41elbaT

Battery

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

discharged and needs to be recharged or replaced. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with a thin film of grease will help inhibit corrosion.

Never place hands near the belts or fan while the generator set is running.

PAGE 46 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — PRE-SETUP

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

connected to the battery ter minals as shown below. The

RED

cable is connected to the positive terminal of the battery , and the BLACK cable is connected to the negativ e terminal of the battery.

Figure 43. Battery Connections

CAUTION

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.

CAUTION

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately.

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

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery terminals when the the manual or auto position (ON). ALWAYS make sure that the Off/Manual/Auto switch is in the OFF position when connecting the battery.

2. Place a small amount of grease around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 47

Off/Manual/Auto

switch is in either

DCA-100SSJU — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and 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 starting system of the equipment.

When the voltage selector switch is in single phase (240/ 120V position), place the AC voltmeter change-over switch to the U-W position and the AC ammeter change over-switch to the U or W position to read the output.

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 15. below when connecting loads.

daoLyBrotcaFrewoP.51elbaT

daoLfoepyTrotcaFrewoP

srotomnoitcudniesahp-elgniS57.0-4.0

CAUTION

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.

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 r ated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

If wattage is not available on the equipment, approximate wattage may be determined by multiplying the nameplate voltage by the nameplate amperage for three-phase: WATTS =1.732 x VOLTAGE x AMPERAGE

CAUTION:

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

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious injury or death may result without this transfer switch.

spmaltnecsednacnI,sretaehcirtcelE0.1

spmalyrucreM,spmaltnecseruolF9.0-4.0

noitacinummoC,secivedcirtcelE

tnempiuqe

Three Phase Load

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

PAGE 48 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

NOTE

If output (kVA) is not given on the equipment nameplate, approximate

0.1

output may be determined by multiplying voltage by amperage by

DCA-100SSJU — GENERAT OR START-UP PROCEDURE

WARNING:

The engine's exhaust contains harmful emissions.

ALWAYS

ventilate the exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

2. Connect the load to the UNV terminals as shown in Figure 45. These terminals can be found on the output terminal panel, (see page 35 Figure 16). To gain access to the output terminals lift the UNV cover. Tighten terminal nuts securely to prevent load wires from slipping out.

Before Starting Engine

1. Check the lubricating oil level prior to starting the engine. Make sure the generator is level. The oil level must be maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase with high grade motor oil. Use a high quality detergent oil classified CC or higher (See Table 3 on page 27).

3. Check the coolant level in the radiator and subtank. Replenish with antifreeze as necessary . Always maintain the coolant lev el between the FULL and LOW markings on the coolant container . Be sure that the r adiator cap is fastened securely.

4. Check the fuel level on the fuel gauge. If fuel is low, fill the fuel tank with clean fresh unleaded automotive diesel. If diesel spillage occurs, completely wipe up the spilled

3. Connect the negative battery cable (BLACK) to the

fuel immediately.

Before Starting Generator and Control Panel

CAUTION:

NEVER start the engine with the

main, GFCI

in the ON position.

1. Be sure to disconnect the electrical load and switch the circuit breakers (Figure 44) to the “OFF” position prior to starting the engine.

load

circuit breakers

main, load

and

G.F.C.I.

Figure 45. UNV Terminal Lugs (Load)

negative post on the battery (Figure 46).

NEGATIVE

POSTIVE

BATTERY

Figure 46. Battery Connections

Figure 44. Main, GFCI and

Load Circuit Breakers

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 49

DCA-100SSJU — GENERATOR START-UP PROCEDURE (MANU AL)

4. Close all engine enclosure doors (Figure 47).

Figure 47. Engine Enclosure Doors

9. Once the engine is warm and the engine is running

5. When starting the generator in COLD weather conditions, press and hold the engine preheat button (Figure 48) .

Figure 48. Engine Pre-Heat Button

10. If the generator is equipped with a Microprocessor

6. Check the voltage selection switch is at the desired voltage (Figure 49).

properly, pull and turn the lev er to ‘RUN (Figure 52)’.

Figure 52. Engine Speed Switch (low)

Engine Control unit (MPEC), set engine speed switch to ‘Low’ (Figure 53).

Figure 53. Engine Speed Switch (low)

Figure 49. Voltage Selection Switch

7. If the generator is equipped with a engine throttle lever, make sure the lever is pushed in and set to ‘IDLE’ (Figure 50).

Figure 50. Engine Throttle Lever (IDLE)

8. If the generator has a starter switch, turn the key to ‘START’ (Figure 51) until the engine starts. Then release the key to set it at ‘OPERATION’ function.

11. Tur n the Auto-Off/Reset-Manual switch to ‘Manual’ to start the engine (Figure 54). Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 54. Auto-Off/Reset-Manual Switch

12. Once the engine is warm and the engine is running properly, set the engine speed switch to ‘High’ (Figure 55).

Figure 51. Engine Speed Switch (low)

PAGE 50 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 55. Engine Speed Switch (high)

DCA-100SSJU — GENERATOR START-UP PROCEDURE (MANU AL)

13. The generator's frequency meter (Figure 56) displays the 60 cycle output frequency in HERTZ.

16. The engine oil pressure gauge (Figure 60) will indicate the oil pressure (kg/ cm operating conditions the oil pressure is approximately 25 psi.

Figure 56. Frequency Meter (Hz)

17. The coolant temperature gauge (Figure 61) will indicate the coolant temperature. Under normal operating

14. The generator's voltage meter (Figure 57) displays the 120 VAC in VOL TS. If the voltage is not within the

conditions the coolant temperature is between 165 and 215 degrees F ahrenheit.

specified frequency tolerance, use the voltage adjustment control knob (Figure 58) to increase or decrease the desired voltage.

of the engine. Under normal

Figure 60. Oil Pressure Gauge

WATER

TEMP

Figure 61. Coolant Temperature Gauge

18. The tachometer (Figure 62) will indicate the speed of

Figure 57. Engine Speed Switch (low)

the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 58. Voltage Adjust Control Knob

15. The ammeter (Figure 59) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator’s alternator.

19. Tur n the MAIN, GFCI and LOAD circuit breakers to their ON position (Figure 63).

Figure 62. Engine Tachometer

Figure 59. Ammeter (No Load)

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 51

Figure 63. Main and GFCI Circuit Breakers

DCA-100SSJU — GENERATOR START-UP PROCEDURE (A UT O)

20. Observe the generator's ammeter (Figure 64) 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.

Figure 64. Ammeter (Load)

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

CAUTION:

Starting the generator in the "AUTO" mode is similar to starting the generator in the "MANUAL" mode, with a few exceptions.

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious

injury

death

may result without this transfer switch.

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.

CAUTION:

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.

When starting generator in Auto mode use the "Manual Startup" procedure except where noted (see below).

1. Perform steps 1 through 10 (Before Starting, page 49-

50) as outlined in the manual starting procedure.

2. Place the Off/Manual/Auto switch (Figure 65) in the

AUTO position (up).

PAGE 52 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

Figure 65. Off/Manual Auto Switch (AUTO)

3. Continue to follow the steps outline in the man ual startup procedure (start at step 13, page 51).

DCA-100SSJU — GENERAT OR SHUTDO WN PROCEDURE

ENGINE SHUTDOWN

To shutdown the generator , use the f ollowing procedure:

6. If the engine is equipped with the engine throttle lev er , turn the key to ‘’STOP’ position (Figure 70).

1. Switch both the MAIN, GFCI and LOAD circuit breakers (Figure 66) to the “OFF” position.

Figure 70. Engine Starter Switch (STOP)

Figure 66. Main, GFCI and Load

circuit breakers

7. Remove the load from the UNV terminal strip.

2. Set the engine speed switch (Figure 67) to the idle (low) position.

Figure 67. Engine Speed Switch

3. If the engine is equipped with the engine throttle lev er , turn and push to ‘IDLE’ position (Figure 68).

Figure 68. Engine Throttle Lever (IDLE)

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

load applied.

5. Turn the Auto-Off/Reset-Manual s witch from the MPEC to “OFF/Reset” position (Figure 69).

Figure 69. Off/Manual Auto Switch

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 53

DCA-100SSJU — MAINTENANCE

General Inspection

Prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks.

Engine Side, Fuel, Oil and Coolant (Refer to the Engine Instruction Manual)

Air Cleaner

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

Fuel Addition

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

Removing Water from the T ank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally remove the drain cock and drain the contents. During cold weather , the greater the empty volume inside the tank, the easier it is for water to condense. This can be reduced by always keeping the tank as full as possible.

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 diesel. 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 page 27, Figure 9.

Generator Storage

For storage of the generator for over 30 days, the following is required:

Drain the fuel tank completely.

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

Clean all external parts of the generator with a cloth.

Cover the generating set and store in a clean, dry place.

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 key switch to the “START” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions, a clogged air cleaner will result in high fuel consumption, loss of power and excessive carbon buildup in the combustion chamber .

PAGE 54 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — MAINTENANCE

61ELBAT

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

leveL

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

noitcetorPtnalooCkcehCdnarotaidaRnaelC

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

srH01

YLIAD

srH052 srH005 srH0001

X X

knaTleuFfoedisnInaelC X

ROTARENEG

smhoM3revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 55

DCA-100SSJU — 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

?tungniniaterepip

diagnosis based on the Engine T roub leshooting (T a ble 17). If the problem cannot be remedied, consult our company's business office or service plant.

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

.tunnethgiT

GNITOOHSELBUORTENIGNE.71ELBAT

.lioenigneroleufdeificepsehtesU

.tratstonseodenignE

.nurtonseodretratS

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?rednilycmorfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

PAGE 56 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.81ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

tsuahxeyargkradrokcalbrehtiE

.devresbosisag

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

.tuptuotneicifeD

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 57

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?gnizieseb

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-100SSJU — TROUBLESHOOTING (GENERATOR/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 diagnosis based on the Engine and Radiator Troubleshooting (Table 19) and the MPEC trouble shooting table (Table 20). If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG&ENIGNE.91ELBAT

MOTPMYSMELBORPELBISSOPNOITULOS

?yrettabdaeD.yrettabecalpeR

retratsdnatratsotsliafenignE

.detatortonseod

retratsdnatratsotsliafenignE

.setator

woltasniamerdnastratsenignE

.deeps

?leufoN.leufddA

?hctiwsretratsevitcefeD.hctiwsecalpeR

?tuodenrub5FesuF.esufecalpeR

?tiucrictaeh-erpnekorB.tiucrictaeh-erpkcehC

?gniriwevitcefeD.gniriwkcehC

?reniartsleufdeggolC.ecalperronaelC

?renaelcriadeggolC.ecalperronaelC

?gniriwdetcennocsiD.gniriwriaperdnakcehC

rewopCAnitneserpegatlovoN

?ecruos

?rotorevitcefeD.rotorecalpeR

egatlovondnasesirdeepsenignE

.ecruosrewopCAnitneserpsi

?gnidniw

rewopCAdnasesirdeepsenignE

ebtonnacrowolootsiegatlov

.desu

yrettabdnasesirdeepsenignE

.noosootsegrahcsid

enignednasesirdeepsenignE

.dedaolrevosmees

?retemtlovevitcefeD.retemtlovecalpeR

?gniriwdetcennocsiD.gniriwriaperdnakcehC

erutamranitiucric-trohsreyaL

?)rotcetorp(rekaerbtiucricevitcefeD .)rotcetorp(rekaerbtiucricecalpeR

niseriwnekorb,tiucric-trohsreyaL

?gnidniwerutamra

?rotalugerenigneevitcefeD.rotalugerecalpeR

?gniriwevitcefeD.gniriwecalperroriapeR

?rotanretlaevitcefeD.rotanretlaecalperroriapeR

?gniraebrotanretladegamaD.sgniraebrotanretlaecalpeR

.)1ER(reifitcerecalpeR

.erutamraecalpeR

.erutamraecalperroriapeR

PAGE 58 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — TROUBLESHOOTING (MPEC)

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

GNITOOHSELBUORTCEPM.02ELBAT

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

thgilleveltnaloocwoL

.nosi

erutrepmettnaloochgiH

.nosithgil

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR ?CEPMninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

.nosithgilknarcrevO

.nosithgildeepsrevO

ro)s(thgilUPMfossoL

.no

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 59

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenCEPM.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenCEPM.relaedotrefeR

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipcitengaM .pukcipcitengamnaelC

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.

Note: If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

, #,

PAGE 60 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU — SUGGESTED SPARE PARTS

DCA-100SSJU W/JOHN DEERE 6068TF150 DIESEL ENGINE 1 TO 3 UNITS

Qty. P/N Description

1 ......... 0601808814 ............ CIRCUIT BREAKER

1 ......... 0601820671 ............ A UTOMA TIC V OL T AGE REGULA T OR

1 ......... 0601840073 ............ RHEOST AT VOL T A GE REGULA T OR

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

1 ......... M3310500003 ......... RADIA T OR HOSE

1 ......... M3310500103 ......... RADIA T OR HOSE

1 ......... 0193601080 ............ RADIAT OR HOSE

5 ......... 0602041290 ............ OIL FILTER

5 ......... 0602042590 ............ FUEL FILTER

5 ......... 0602046377 ............ AIR ELEMENT

1 ......... 0602122093 ............ UNIT OIL PRESSURE

1 ......... 0602123261 ............ UNIT W ATER PRESSURE

1 ......... 0601810245 ............ BULB

3 ......... AR51481................. KEY, STARTER SWITCH S/N7400001 TO 7400295

1 ......... ECU8899N.............. ENGINE CONTROLLER S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 61

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

GENERATOR ASSY.

DCA-100SSJU --- GENERAT OR ASSY.

PAGE 62 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- GENERAT OR ASSY.

GENERATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 C0110000220 ROTOR ASSY. 1 1-1 FIELD ASSY 1 1-2 8101070033 FAN 1 1-3 8101611014 COUPLING DISK 5 1-4 8101015003 BALANCING PLATE 1 1-5 0012110030 HEX. HEAD BOLT 8 1-6 0042510000 LOCK WASHER 8 1-7 8101026013 SET PLATE, RECTIFIER 1

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

1-9 0601822601 SURGE ABSORBER ........................... 1 ............ ERZ-M14JK21A

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

1-15 0071906311 BEARING ............................................. 1 ............ 6311DDU C3

2 C0130000103 STRATOR ASSY 1 S/N7400001 TO 7400356

C0130200003 STRATOR ASSY. 1 S/N7400357~ 3 0845041804 GROMMET 2 4 8101315202 END BRACKET 1 5 8101350013 FIELD ASSY EXCITER 1

6 0012110070 HEX. HEAD BOLT ................................ 4 ............ S=26

7 0042610000 LOCK WASHER 4 8 0041210000 PLAIN WASHER 4 9 0010110035 HEX. HEAD BOLT 6 10 0040010000 LOCK WASHER 6 11 0041210000 PLAIN WASHER 6 12 8101310014 COVER, BEARING 1 13 8131312014 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 LOCK WASHER 2 19 0041206000 PLAIN WASHER 2

20 8101614003A COUPLING RING ................................ 1 ............ REPLACES M2163400003

21 0013904044 HEX. HEAD BOLT ................................ 8 ............ S/N7400001 TO 74001060

034320415 HEX. HEAD BOLT ................................ 8 ............ SN 7400161~

22 0043604000 LOCK WASHER 8

23 0070506306 BEARING ............................................. 1 ............6303ZZ

24 0012810030 HEX. HEAD BOLT 8

25 0010310035 HEX. HEAD BOLT ..............................12 ............S/N7400001 TO 7400160

0012810030 HEX. HEAD BOLT ..............................12 ............7400161~

26 0042510000 LOCK WASHER ................................. 1 2 ............ S/N7400001 TO 7400160

27 8111332014 COVER, FAN 1

28 0605000063 RUBBER SUSPENSION ...................... 2 ............ KA-120SS

29 0030016000 HEX. NUT 2

0040016000 LOCK WASHER 2 30 0600815000 NUT 1

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 63

CONTROL BOX ASSY.

DCA-100SSJU --- CONTROL BO X ASSY.

PAGE 64 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

M3246700404 WIRE HARNESS, GENERATOR 1

1 M3213000202 CONTROL BO X ........................................... 1 ......... S/N7400001 TO 7400033

M3213000212 CONTROL BO X ........................................... 1 ......... S/N7400034 TO 7400150

M3213000222 CONTROL BO X ........................................... 1 ......... S/N7400151 TO 7400295

M3213000232 CONTROL BO X ........................................... 1 ......... S/N7400296~

2 0601808814 CIRCUIT BREAKER .................................... 1 ......... KAF362501021 3P 250A

3 0021005080 MACHINE SCREW 4

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

5 0027104015 MACHINE SCREW 4

6 0601820671 AUTOMATIC VOL T A GE REGULA T OR .......... 1 ......... NT A-5A-2DB

7 0027105010 MACHINE SCREW ...................................... 4 ......... S/N 7400001 TO 7400150

0027105015 MACHINE SCREW ...................................... 4 ......... S/N7400151~

8 0601806118 CURRENT TRANSFORMER........................ 3 ......... 814-943 200/5A

9 0027106015 MACHINE SCREW 6 10 0601820845 OVER CURRENT RELAY 1 LR2D1308 11 0601820846 OVER CURRENT RELAY 1 LA7D1064 12 M1260600004 FITTING BRACKET 1 S/N7400001 TO 7400150 13 0027104015 MACHINE SCREW 2

14 0027104010 MACHINE SCREW ...................................... 2 ......... S/N 7400001 TO 7400150

15 M3213500003 CONTROL BO X COVER.............................. 1 ......... S/N7400001 TO 7400133

M3213500013 CONTROL BO X COVER.............................. 1 ......... S/N7400034~

16 0016906015 HEX. HEAD BOLT 4

17 M3923100004 SELECTOR SWITCH................................... 1 ......... VY-125

18 M3276600004 SPACER 8 19 M3213600003 SWITCH BRACKET 1 20 0330000295 EDGING 2 21 M3260500004 SWITCH BOARD 1 22 0021104010 MACHINE SCREW 4 23 0016006015 HEX. HEAD BOLT 6

24 M3213600114 SWITCH COVER ......................................... 1 ......... REPLACES M3213600104

25 0016906015 HEX. HEAD BOLT 4 26 0016906015 HEX. HEAD BOLT 10

0040506000 TOO THED W ASHER 1

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 65

CONTROL BOX ASSY.

DCA-100SSJU --- CONTROL BOX ASSY.

PAGE 66 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. ITEM QTY. REMARKS

27 M3223000203 CONTROL PANEL 1

28 0601807630 FREQUENCY METER................................. 1 ......... 264250 DJDJ9

29 0601808953 AC AMMETER............................................. 1 ......... 260240LSLS1JCA

30 0601801040 CHANGE-O VER SWITCH, AMMETER ....... 1 ......... SL-2AS

31 0601806813 AC VOLTMETER.......................................... 1 ......... 260244SJSJ1

32 0601801041 CHANGE-O VER SWITCH, V OLTMETER .... 1 ......... SL-2VS

33 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ......... 1 ......... RA20A2SE102BJ 2W 1K OHM

34 0601840121 KNOB .......................................................... 1 ......... 25N

35 M1223100004 STOPPER 1 36 0027105015 MACHINE SCREW 2 37 0027105015 MACHINE SCREW 4 38 M9220100004 SET SCREW 1 39 0080200007 SNAP RING 1

40 0601821370 RECTIFIER.................................................. 1 ......... DE 4503 REPLACES 0601823240

41 0027104020 MACHINE SCREW ...................................... 1 ......... S/N7400001 TO 7400205

AND 7400296~

0027105020 MACHINE SCREW ...................................... 1 ......... S/N7400206 TO 7400295

42 0602200478 EMERGENCY RELAY ................................. 1 ......... 10701-60602,3

S/N7400001 TO 7400295

43 0027105040 MACHINE SCREW ...................................... 2 ......... S/N7400001 TO 7400295

44 0602202592 STARTER RELAY ........................................ 1 ......... AT141011

45 011808015 MACHINE SCREW ...................................... 2 ......... REPLACE 0027106015

46 0601821370 RECTIFIER.................................................. 1 ......... DE 4503 REPLACES

0601823240 S/N7400296~

47 DYN10794000012 CONTROLLER ............................................. 1 ......... REPLACES 0602202599 S/N7400296~

MPS6724 SPEED SENSOR ........................................ 1 ......... REPLACES 0602120485 S/N7400296~

48 0027105015 MACHINE SCREW ...................................... 4 ......... S/N7400296~

49 LY2US12VDC RELAY ......................................................... 1 ......... REPLACES 0601823768

S/N7400296 TO 7400310

0601827656 RELAY ......................................................... 1 ......... LY2-D 12VD S/N7400311~

0601823109 BASE........................................................... 1 ......... PTS 08A-E S/N 7400296~

PYCA1 CLIP............................................................. 2 ......... REPLACES 0601824400S/N7400296~

50 0601823223 RECTIFIER.................................................. 1 ......... 30D4 S/N7400296 TO 7400310

51 0027104020 MACHINE SCREW ...................................... 2 ......... S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 67

ENGINE AND RADIATOR ASSY.

DCA-100SSJU ENGINE AND RADIA T OR ASSY.

PAGE 68 — DCA-100SSJU — PARTS AND OPERATION MANUAL(STD) — REV. #2 (05/03/01)

DCA-100SSJU ENGINE AND RADIA T OR ASSY.

ENGINE AND RADIATOR ASSY. NO. PART NO. ITEM QTY. REMARKS

1 M3923200014 ENGINE.......................................... 1 ........... JOHN DEERE 6068TF S/N7400001 TO 7400356

M3925200004 ENGINE.......................................... 1 ........... JOHN DEERE 6068TF150 S/N7400357~

0602011491 FAN BELT 1

1-1 0602041290 ELEMENT, OIL FILTER ................. 1 ........... JOHN DEERE RE59754A

1-2 0602042590 ELEMENT, FUEL FILTER .............. 1 ........... JOHN DEERE RE92418

1-3 0602014297 ELECTRIC HEATER ...................... 1 ........... JOHN DEERE RE29658 S/N 7400001 TO 7400175

ELECTRIC HEATER ASSY. ........... 1 ........... JOHN DEERE RE502668 S/N 7400176~

2 0602060010 BLOWER FAN ............................... 1 ...........422198

3 0602061000 FAN SPACER ................................. 1 ........... JOHN DEERE R81911

4 0012110095 HEX. HEAD BOLT .......................... 4 ........... S=31

5 030210250 LOCK WASHER............................. 4 ........... REPLACES 0042510000

6 M2303200303 ENGINE FOOT 2

7 0131151240 HEX. HEAD BOLT .......................... 6 ........... REPLACES 0010312030

8 0040012000 LOCK WASHER 6

9 0605000060 RUBBER SUSPENSION ............... 2 ........... KA-80SS

10 0030012000 HEX. NUT 2 11 0040012000 LOCK WASHER 2

12 0602011988 RADIATOR..................................... 1 ........... JOHN DEERE RE52824

0602012723 RADIATOR..................................... 1 ........... C2810060000 S/N 7400206~

12-1 0602011067 CAP ................................................ 1 ...........S/N7400001~7400205

0602011066 CAP ................................................ 1 ...........S/N7400206~

12-2 0199101200 HOSE ............................................. 1 ...........S/N7400206~

13 0602010795 FAN COVER ................................... 1 ........... C2810044210 S/N7400001 TO 7400205

14 0013006008 HEX. HEAD BOLT .......................... 8 ........... S/N7400001 TO 7400205

15 0043106000 PLAIN WASHER ............................ 8 ........... S/N7400001 TO 7400205

16 M3310200204 RADIATOR BRACKET .................. 1 ........... S/N7400001 TO 7400205

17 M3310200404 RADIATOR BRACKET .................. 1 ........... S/N7400001 TO 7400205

18 0013006008 HEX. HEAD BOLT .......................... 8 ........... S/N7400001 TO 7400205

19 030206150 LOCK WASHER ............................. 8 ........... REPLACES 0043006000 S/N7400001 TO 7400205

20 0043106000 PLAIN WASHER ............................ 8 ........... S/N7400001 TO 7400205

21 011008020 HEX. HEAD BOLT .......................... 8 ...........REPLACES 0016908020

22 0138102000 PLUG ............................................. 1 ...........S/N7400001 TO 7400205

23 M3310500003 RADIATOR HOSE ......................... 1 ...........S/N7400001 TO7400205

M3310500403 RADIATOR HOSE ......................... 1 ...........S/N7400206~

24 M3310500103 RADIATOR HOSE ......................... 1 ........... S/N 7400001 TO 7400205

M3310500503 RADIATOR HOSE ......................... 1 ...........S/N7400206~

25 0605515148 HOSE BAND .................................. 2 ........... 5040

26 0605515147 HOSE BAND .................................. 2 ........... 5032

27 0605512190 HOSE JOINT ................................. 1 ........... S/N7400001 TO 7400205

28 7812014003B DRAIN JOINT ................................. 1 ........... REPLACES M2320300103

S/N7400001 TO 7400205

29 M9200200004 DRAIN JOINT ................................. 1 ........... S/N7400001 TO 7400205

30 0150000018 O RING .......................................... 1 ........... A P18 S/N7400001 TO 7400205

31 011206020 HEX. HEAD BOLT .......................... 2 ...........REPLACES 0016906020 S/N7400001 TO 7400205

32 0191300580 DRAIN HOSE ................................. 1 ........... S/N7400001 TO 7400205

33 0605515189 HOSE BAND .................................. 2 ........... 91004 S/N7400001 TO 7400205

34 0602046258 AIR CLEANER ............................... 1 ...........FRG100297

0602046377 ELEMENT, AIR CLEANER ............ 1 ........... P778214

35 0602040650 INDICATOR, AIR CLEANER ......... 1 ........... RBX00-2252

36 0603306385 NIPPLE ........................................... 1 ........... S/N 7400001 TO 7400004

37 0602040596 BAND, AIR CLEANER.................... 2 ...........P 00-4076

38 011008020 HEX. HEAD BOLT .......................... 4 ...........REPLACES 0016908020

DCA-100SSJU — PARTS AND OPERATION MANUAL(STD)— REV. #2 (05/03/01) — PAGE 69

ENGINE AND RADIATOR ASSY.

DCA-100SSJU ENGINE AND RADIATOR ASSY.

PAGE 70 — DCA-100SSJU — PARTS AND OPERATION MANUAL(STD) — REV. #2 (05/03/01)

DCA-100SSJU ENGINE AND RADIA T OR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. ITEM QTY. REMARKS

39 020108060 HEX. NUT....................................... 4 ...........REPLACES 0207008000

40 M3373100003 HOSE, AIR CLEANER 1

41 0605515146 HOSE BAND .................................. 1 ........... 5035

42 0605515200 HOSE BAND .................................. 1 ........... 5072

43 0602022563 ADAPTER ...................................... 1 ........... 10-M18X1.5 F80X-S

44 0602021165 O RING .......................................... 1 ........... 411 S/N7400001 TO 7400205

45 0602022561 90

46 0602022562 UNION............................................ 1 ........... 10WTX-WLN-S S/N7400001 TO 7400295

47 0602022792 SWIVEL .......................................... 1 ........... 30682-10-10 S/N7400001 TO 7400295

48 0602021070 CAP ................................................ 1 ...........10FNTX-S

49 0602021573 DRAIN HOSE................................. 1 ........... 836-10 S/N 7400001 TO 7400295

0269200406 DRAIN HOSE................................. 1 ........... 836-10 S/N 7400296~

50 M9300000203 RESERVE TANK 1

51 0802010900 CAP, RESERVE TANK.................... 1 ...........REPLACES 0602010900

52 M3316100104 BRACKET, RESERVE TANK 1

53 011008020 HEX. HEAD BOLT .......................... 2 ...........REPLACES 0016908020

54 0193601080 HOSE 1

55 M2260600014 RELAY BRACKET .......................... 1 ........... S/N7400001 TO 7400175

M2260600024 RELAY BRACKET .......................... 1 ........... S/N7400176~

56 0602202597 RELAY ............................................ 1 ........... AL64309 S/N7400001 TO 7400175

0602202592 RELAY ............................................ 1 ...........AT141011 S/N7400176~

57 0017105015 HEX. HEAD BOLT .......................... 1 ........... S/N7400001 TO 7400175

011808015 MACHINE SCREW ........................ 2 ........... REPLACES 0027106015 S/N7400176~

58 M3313100004 RADIATOR COVER ....................... 1 ...........S/N7400001 TO 7400205

M3313100204 RADIATOR COVER ....................... 1 ...........S/N7400206~

59 011008020 HEX. HEAD BOLT .......................... 4 ...........REPLACES 0016908020

60 030206150 LOCK WASHER ............................. 8 ........... REPLACES 0043006000 S/N7400001 TO 7400205

61 011008020 HEX. HEAD BOLT .......................... 1 ...........REPLACES 0016908020

62 0602122281 OIL SWITCH .................................. 1 ........... 1718939011

63 0602123282 WATER SWITCH ........................... 1 ...........1518183041

64 M9200100404 ADAPTER 1

65 M9200100704 ADAPTER ...................................... 1 ...........S/N7400004~

66 0605511395 VALVE............................................. 1 ........... XV500P-8 S/N7400296~

67 DYNC70025000012 ACTUATOR ................................... 1 ........... REPLACES 0602150093 S/N7400296~

68 M3356200004 STOPPER BRACKET .................... 1 ........... S/N7400296~

69 012210020 HEX. HEAD BOLT .......................... 1 ...........REPLACES 0017110020 S/N7400296~

70 011206020 HEX. HEAD BOLT .......................... 1 ...........REPLACES 0016906020 S/N7400296~

71 0207006000 HEX. NUT ....................................... 1 ...........S/N7400296~

72 0603306590 CONNECTOR ............................... 1 ...........10WFTX-S S/N7400296~

73 0603300285 ROCK NUT .................................... 1 ........... 10WLN S/N7400296~

74 0603306395 HOSE JOINT ................................. 1 ...........30182810 S/N7400296~

ELBOW .................................... 1 ........... 33982-10-10+

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 71

DCA-100SSJU --- ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

S/N 700001 T O 7400295

PAGE 72 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

S/N 7400296~

DCA-100SSJU --- ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY. NO. PARTS NO. ITEM QTY. REMARKS

M3357200002 WIRE HARNESS, ENGINE ................... 1 ........... S/N7400001 TO 7400175

M3357200012 WIRE HARNESS, ENGINE ................... 1 ........... S/N7400176 TO 7400295

M3359200302 WIRE HARNESS, ENGINE ................... 1 ........... S/N7400296~

1 M1354300304 SLIDE LEVER ....................................... 1 ...........S/N7400001 TO 7400295

2 0601840190 KNOB .................................................... 1 ........... REPLACES M9320000004

S/N7400001 TO 7400295

3 0036003000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

4 0605804150 SPRING................................................. 1 ........... 5639 S/N7400001 TO 7400295

5 0041208000 PLAIN WASHER.................................... 2 ........... S/N7400001 TO 7400295

6 M1354200004 BRACKET ............................................. 1 ...........S/N7400001 TO 7400295

7 0207008000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

8 0030008000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

9 0605010550 SNAP PIN .............................................. 1 ...........222NPH10Z S/N7400001 TO 7400295

10 M3354300104 GOVERNOR ROD ................................ 1 ........... S/N7400001 TO 7400295

11 0602180106 BALL JOINT .......................................... 1 ........... LHSA8 DE161 S/N7400001 TO 7400295

12 0030008000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

13 0602180107 BALL JOINT .......................................... 1 ........... LHSSE8 DLE161 S/N7400001 TO 7400295

14 0036508000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

15 0207006000 HEX. NUT .............................................. 1 ...........S/N7400001 TO 7400295

0041206000 PLAIN WASHER.................................... 2 ........... S/N7400001 TO 7400295

16 0602100056 STARTER SWITCH .............................. 1 ........... JOHN DEERE AR58126

S/N7400001 TO 7400295

AR51481 KEY, STARTER SWITCH ...................... 1 ........... S/N7400001 TO 7400295

0602100028 SET NUT ............................................... 1 ........... JOHN DEERE R44342 S/N7400001 TO 7400295

0602100029 SET WASHER ....................................... 1 ........... JOHN DEERE A4827R S/N7400001 TO 7400295

17 0601831594 COLD STARTING BUTTON ................ 1 ........... JOHN DEERE R39554 S/N7400001 TO 7400220

0601831585 COLD STARTING BUTTON ................ 1 ........... 44047 S/N 7400221~

0601831584 CAP ....................................................... 1 ...........JOHN DEERE T55585 S/N7400001 TO 7400220

0601831588 CAP ....................................................... 1 ........... 44053 S/N 7400221~

18 0602120096 TACHOMETER ..................................... 1 ...........103678

19 0602122093 OIL PRESSURE GAUGE ...................... 1 ...........100174

20 0602122271 UNIT, OIL PRESSURE.......................... 1 ........... REPLACES 0602122271

S/N7400001 TO 7400077

0602122272 UNIT, OIL PRESSURE.......................... 1 ........... 108497 S/N7400078~

21 0602123092 WATER TEMPERATURE GAUGE ........ 1 ........... 100182

22 0602123261 UNIT, WATER TEMPERATURE ............ 1 ........... 0202500

23 0602121080 CHARGING AMMETER ........................ 1 ........... 100158

24 0602125090 FUEL GAUGE ....................................... 1 ........... 100176

25 0602103092 ALARM LAMP ....................................... 1 ...........PL-05 S/N7400001 TO 7400295

0601810245 BULB ..................................................... 2 ........... E-10 T-10 DC18V S/N7400001 TO 7400295

26 0601810141 PANEL LIGHT ....................................... 1 ...........9826800370

27 0601831330 SWITCH, PANEL LIGHT ....................... 1 ........... 900001

28 ECU9988N ENGINE CONTROLLER ...................... 1 ........... REPLACES 0602202546 S/N7400296~

28-1 0601831340 SWITCH ................................................ 1 ........... 7562K4 S/N7400296~

0600500091 NAME PLATE ........................................ 1 ........... S/N7400296~

29 0601831395 SWITCH ................................................ 1 ........... 7302K36 S/N7400296~

30 0027104035 MACHINE SCREW ............................... 2 ........... S/N 7400296~

0207004000 HEX. NUT .............................................. 2 ...........S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 73

OUTPUT TERMINAL ASSY .

DCA-100SSJU --- OUTPUT TERMINAL ASSY.

PAGE 74 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY . NO. PART NO. ITEM QTY REMARKS

1 M3230700003 TERMINAL PANEL 1 2 M9220100304 OUTPUT TERMINAL BOLT 5

3 0801830804 TIE BOLT ........................................................ 5 .........REPLACES M9220100404

4 0039316000 HEX. NUT 10 5 0040016000 LOCK WASHER 15 6 0041416000 PLAIN WASHER 20

7 0012108035 HEX. HEAD BOLT .......................................... 5 .........REPLACES 0016908035

8 M3236100303 TERMINAL COVER ....................................... 1 .........S/N7400001 TO 7400205

M3236100313 TERMINAL COVER ....................................... 1 .........S/N7400206 TO 740295

M3238100103 TERMINAL COVER ....................................... 1 ......... S/N7400296

9 M3236100104 OUTPUT WINDOW 1

10 0605010040 HINGE ............................................................ 2 ......... TH-TM122

11 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT ....................................................... 4 ......... REPLACES 0030003000

58413 PLAIN WASHER............................................. 4 .........REPLACES 0041203000

12 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT ....................................................... 4 ......... REPLACES 0030003000

13 011206020 HEX. HEAD BOLT .......................................... 2 .........REPLACES 0016906020

14 0016906015 HEX. HEAD BOLT 4

15 M3236400004 CABLE OUTPUT COVER .............................. 1 ......... REPLACES M2236400004S

16 M3236300004 SUPPORTER, CABLE OUTLET COVER ..... 1 ......... REPLACES M2236400004

17 0016906020 HEX. HEAD BOLT 6

18 0601808803 CIRCUIT BREAKER ....................................... 2 .........QOU 120B 1P 20A

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

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

22 0601812597 RECEPTACLE................................................ 2 ......... REPLACES 0601812598;

GF530EM 125V 20A X2

23 0601811034 RECEPTACLE................................................ 3 ......... REPLACES 0601812538 CS6369 250V 50A

24 0027104015 MACHINE SCREW 1 0

0030004000 HEX. NUT .....................................................10 .........REPLACES 0207004000

25 M3236100213 TERMINAL COVER ....................................... 1 ......... REPLACES M3236100203

26 012212045 HEX. HEAD BOLT .......................................... 2 .........REPLACES 0010112045

27 031112230 PLAIN WASHER ............................................. 2 .........REPLACES 0041212000

28 M9310200004 STAY RUBBER 2 29 0030012000 NUT 2

30 M2354200004 SUPPORTER, GOVERNOR ROD ................ 1 ......... S/N7400001 TO 7400295

31 011106015 HEX. HEAD BOLT .......................................... 2 .........REPLACES 0016906015

S/N7400001~7400295

32 M3455600004 PLUG.............................................................. 2 .........S/N7400296~

33 0021304015 MACHINE SCREW ........................................ 4 ......... REPLACES 0027104015 S/N7400296~

34 0601815194 TERMINAL ..................................................... 1 .........601-GP-02 SN7400296~

35 0021304015 MACHINE SCREW ........................................ 2 ......... REPLACES 0027104015 S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 75

BATTERY ASSY.

DCA-100SSJU --- BATTER Y ASSY.

PAGE 76 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- BATTER Y ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 0602220196 BATTERY ........................................1........... 4D-2

2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 0040006000 LOCK W ASHER 2 6 M3346900004 BATTERY CABLE 1 7 M3346900104 BATTERY CABLE 1 8 CABLE 1 9 0017112025 HEX. HEAD BOLT 1

0040512000 TOOTHED WASHER 1

10 012210020 HEX. HEAD BOLT...........................1........... REPLACES 0017110020

0040510000 TOOTHED WASHER 1

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 77

BATTERY ASSY.

DCA-100SSJU --- MUFFLER ASSY.

PAGE 78 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- MUFFLER ASSY.

BATTERY ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M3330100002 MUFFLER .......................................... 1 ....... S/N85000002 TO 74000053

0602300167 MUFFLER .......................................... 1 ....... 27299N S/N74000054~

2 012210025 HEX. HEAD BOLT.............................. 4 ....... REPLACES 0016910025

3 M3333000303 EXHAUST PIPE 1

4 0602325066 CLAMP............................................... 1 ....... M001432

5 M3333200004 GASKET 1 6 00017110040 HEX. HEAD BOLT 4 7 M33330400304 COVER 1 8 M33330400403 BRACKET 1

9 011008020 HEX. HEAD BOLT.............................. 4 ....... REPLACES 0016908020

10 0602326061 U BOLT S ET ...................................... 1 ....... 89547K

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 79

FUEL TANK ASSY.

DCA-100SSJU --- FUEL TANK ASSY.

PAGE 80 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M3363000202 FUEL T ANK 1-1 0605505070 CAP, FUEL TANK 1 2 M3363200204 TANK BAND 2 3 M9310500104 SUPPORTER SHEET 4

4 011008020 HEX. HEAD BOLT.............................. 2 ....... REPLACES 0016908020

5 020108060 HEX. NUT .......................................... 2 ....... REPLACES 0037908000

S/N7400001 TO 74000026

0273080000 HEX. NUT .......................................... 2 ....... S/N74000027~

031108160 PLAIN WASHER ................................ 2 ....... REPLACES 0041208000

S/N7400001 TO 7400026

6 0222100660 R UBBER SHEET 2

7 1502025103C DRAIN JOINT .................................... 1 ....... REPLACES M9200000003

8 M9200200004 DRAIN BOLT 1

9 0150000018 O RING .............................................. 1 ....... A P18

10 011206020 HEX. HEAD BOLT.............................. 2 ....... REPLACES 0016906020

11 0M1363400104 DRAIN HOSE 1

12 0605515198 HOSE BAND...................................... 2 ....... 5008

13 0602042420 FUEL FILTER ..................................... 1 ....... PTG15P

14 0602042601 LEAK-OFF LINE ................................ 1 ....... JOHN DEERE RE67050

15 0191300450 SUCTION HOSE 1 16 0191301800 SUCTION HOSE 1 17 0191302200 RETURN HOSE 1

18 0605515189 HOSE BAND...................................... 1 ....... 91004

19 0605515109 HOSE BAND...................................... 5 ....... RS-8010

20 0602220911 CLAMP............................................... 1 ....... RCT-2010

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 81

ENCLOSURE ASSY.

DCA-100SSJU --- ENCLOSURE ASSY.

ADD THE FOLLO WING DIGITS AFTER THE P AR T NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MA Y BE REQ UIRED .

5 -BLACK 6 -CATERPILLAR YELLO W 7 -CATO GOLD 8 -RED

PAGE 82 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M3413000202 BASE ............................................... 1 ......... S/7400001 TO 7400205

M3413000212 BASE ............................................... 1 ......... S/N7400206 TO 7400295

M3413000222 BASE ............................................... 1 ......... S/N7400296~

2 M1413400004 UNDER COVER 1

3 011008020 HEX. HEAD BOLT............................ 2 ......... REPLACES 0016908020

4 M3423000302 FRONT FRAME ............................... 1 ......... S/N7400001 TO 7400205

M3423000602 FRONT FRAME ............................... 1 ......... S/N7400206~

M3493100203 ACOUSTIC SHEET ......................... 1 ......... S/N7400001 TO 7400205

M3493100503 ACOUTSTIC SHEET ....................... 1 ......... S/N7400206~

5 012210025 HEX. HEAD BOLT............................ 6 ......... REPLACES 0016910025

6 M3493100304 ACOUSTIC SHEET 1

7 011008020 HEX. HEAD BOLT...........................14......... REPLACES 0016908020

8 M3433000102 CENTER FRAME 1

M3493200004 ACOUSTIC SHEET 1

9 0010114040 HEX. HEAD BOLT 12

020114110 HEX. NUT .......................................12......... REPLACES 0030014000

030214350 LOCK WASHER ..............................24......... REPLACES 0040014000

031114260 PLAIN WASHER .............................24......... REPLACES 0041214000

10 M3443000202 REAR FRAME ................................. 1 ......... S/N7400001 TO 7400295

M3443000212 REAR FRAME ................................. 1 ......... S/N7400296~

11 012210025 HEX. HEAD BOLT............................ 4 ......... REPLACES 0016910025

12 M3443300203 REAR COVER 1 13 M3443300303 DUCT , REAR CO VER 1

M3493300303 ACOUSTIC SHEET 1

14 0207006000 HEX. NUT 1 2

15 011008020 HEX. HEAD BOLT...........................10......... REPLACES 0016908020

16 M3443200103 REAR DOOR.................................... 1 ......... S/N7400001 TO 7400099

M3443200113 REAR DOOR.................................... 1 ......... S/N7400100~

17 M3443600104 WINDOW PLATE 1

18 020106050 HEX. NUT .......................................10......... REPLACES 0037906000 AND 0207306000

952404470 PLAIN WASHER .............................20......... REPLACES 0041206000 AND 0041206000

19 89114000002 DOOR HANDLE ASSY. .................... 1 ......... REPLACES M9113000002

20 0027106016 MACHINE SCREW .......................... 4 ......... REPLACES 0021806015

020106050 HEX. NUT ........................................ 4 ......... REPLACES 0030006000

21 M9110100204 HINGE 2 22 M9116100004 WASHER 2

23 011008020 HEX. HEAD BOLT............................ 3 ......... REPLACES 0016908020

24 0845031504 BLIND PLUG.................................... 2 ......... REPLACES M9310000004

25 M3463100203 ROOF PANEL 1

M3493500203 ACOUSTIC SHEET 1

26 M3463200102 ROOF PANEL 1

M3493500303 ACOUSTIC SHEET 1

27 M3463500104 OVER COVER, FRONT FRAME 1

28 011008020 HEX. HEAD BOLT...........................37......... REPLACES 0016908020

29 1625165103 BONNET CAP.................................. 1 ......... REPLACES M9310000103

30 1625165204 CHAIN ASSY. .................................. 1 ......... REPLACES M1483600204

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 83

ENCLOSURE ASSY.

DCA-100SSJU --- ENCLOSURE ASSY.

PAGE 84 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. ITEM QTY. REMARKS

31 M3453200112 SPLASHER PANEL ......................... 1 ......... REPLACES M3453200102

S/N7400001 TO 7400026

M3453200112 SPLASHER PANEL ......................... 1 ......... S/N7400027 TO 7400205

M3453200122 SPLASHER PANEL ......................... 1 ......... S/N7400206 TO 7400295

M3453200132 SPLASHER PANEL ......................... 1 ......... S/N7400296~

32 011208060 HEX. HEAD BOLT............................ 4 ......... REPLACES 0016908055

33 012210025 HEX. HEAD BOLT............................ 2 ......... REPLACES 0016910025

34 M3453000703 SIDE DOOR 1

M3493400704 ACOUSTIC SHEET 1

35 M3453000603 SIDE DOOR 1

M3493400804 ACOUSTIC SHEET 1

36 M3453000503 SIDE DOOR 1

M3493401004 ACOUSTIC SHEET 1

37 M3453000403 SIDE DOOR 1

M3493401104 ACOUSTIC SHEET 1

38 M3453300303 DUCT 1

M3493400904 ACOUSTIC SHEET 1

39 M3453300503 DUCT 1

M3493401404 ACOUSTIC SHEET 1

40 M3453300203 DUCT 1

M3493401204 ACOUSTIC SHEET 1

41 0207006000 HEX. NUT 2 5

42 89114000002 DOOR HANDLE ASSY. .................... 4 ......... REPLACES M9113000002

43 0027106016 MACHINE SCREW .........................16......... REPLACES 0021806015

020106050 HEX. NUT .......................................16......... REPLACES 0030006000

44 M9110100204 HINGE 4 45 M9110100304 HINGE 4 46 M9116100004 WASHER 8

47 011008020 HEX. HEAD BOLT............................ 9 ......... REPLACES 0016908020

48 0601850097 DOOR ST OPPER 8 49 0027208025 MACHINE SCREW 8

50 0845031504 BLIND PLUG.................................... 8 ......... REPLACES M9310000004

51 M3453700004 DOOR BRACKET 1

52 011106015 HEX. HEAD BOLT............................ 4 ......... REPLACES 0016906015

53 011008020 HEX. HEAD BOLT............................ 1 ......... REPLACES 0016908020

0040508000 TOOTHED WASHER 1

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 85

ADD THE FOLLO WING DIGITS AFTER THE P AR T 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 YELLO W 7 -CATO GOLD 8 -RED

RUBBER SEAL ASSY.

DCA-100SSJU --- RUBBER SEAL ASSY.

PAGE 86 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO. PART N O. ITEM QTY. REMARKS

1 0228900890 R UBBER SEAL 3 2 0229200810 R UBBER SEAL 1 3 0228901020 R UBBER SEAL 2 4 0228900990 R UBBER SEAL 4 5 0228900955 R UBBER SEAL 4 6 0228900470 R UBBER SEAL 2 7 0229201100 R UBBER SEAL 4 8 0229201040 R UBBER SEAL 1 9 0228800970 R UBBER SEAL 2 10 0228800590 R UBBER SEAL 1 11 0228800630 R UBBER SEAL 1 12 0228100665 R UBBER SEAL 1 13 0228100300 R UBBER SEAL 1 14 0228100370 R UBBER SEAL 1 15 0228100280 R UBBER SEAL 1 16 0228100365 R UBBER SEAL 1 17 0228100070 R UBBER SEAL 1

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 87

DECAL ASSY.

DCA-100SSJU --- DECALS

PAGE 88 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

DCA-100SSJU --- DECALS

DECAL ASSY.

NO. PART NO. ITEM QTY. REMARKS

1 M1550000204 DECAL; NO TE...................................................... 1 ......... M15000020

2 M1550000703 DECAL; AUXILIARY OUTPUT ............................. 1 ......... M15000070

3 M3550000304 DECAL; NO TE...................................................... 1 ......... M35000030

4 M3550000402 DECAL; GENERATOR CONTROL........................ 1 ......... M35000040

5 M3550000202 DECAL; ENGINE OPERATING ............................ 1 ......... M35000020 S/N7400001 TO 7400295

M3550000212 DECAL; ENGINE OPERA TING ............................ 1 ......... M35000021 S/N 7400296~

6 M9500000004 DECAL; OIL DRAIN PLUG ................................... 1 ......... M90000000

7 M9500100004 DECAL; W A TER ................................................... 1 ......... M90010000

8 M8400100104 DECAL; WATER DRAIN PLUG............................. 1 ......... M90010010 S/N7400001 TO 7400205

9 M9500300004 DECAL; - .............................................................. 1 ......... M90030000

10 M9500300104 DECAL; + ............................................................. 1 ......... M90030010

11 M9500500004 DECAL; DIESEL FUEL ........................................ 1 ......... M90050000

12 M9500500104 DECAL; FUEL DRAIN PLUG................................ 1 ......... M90050010

13 M9503000004 DECAL; W ARNING ............................................... 2 ......... M90300000

14 M9503000103 DECAL; WATER, OIL CHECK .............................. 1 ......... M90300010

15 M9503100004 DECAL; W ARNING ............................................... 1 ......... M90310000

16 M9503200004 DECAL; W ARNING ............................................... 1 ......... M90320000

17 M9510100004 DECAL; CA UTION................................................ 1 ......... M91010000

18 M9510200002 DECAL; MQ ......................................................... 1 ......... M91020000

19 M9520000004 DECAL; GROUND ................................................ 1 ......... M92000000

20 M9520000104 DECAL; AMMETER CHANGE OVER SWITCH ... 1 ......... M92000010

21 M9520000204 DECAL; VOL TMETER CHANGE OVER SWITCH 1 ......... M92000020

22 M9520100004 DECAL; W ARNING ............................................... 2 ......... M92010000

23 M9520100204 DECAL; CA UTION................................................ 1 ......... M92010020A

24 M9520100304 DECAL; SAFETY INSTRUCTIONS...................... 1 ......... M92010030

25 M9520100404 DECAL; D ANGER ................................................ 1 ......... M92010040

26 M9520100503 DECAL; W ARNING ............................................... 1 ......... M92010050

27 M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ..... 1 ......... M92020000

28 M9520200104 DECAL; OVER CURRENT RELAY....................... 1 ......... M92020010

29 M3560100003 STRIPE; WHISPER WATT 1 30 M3560100103 STRIPE; MP POWER 2 31 M3560100203 STRIPE 2 32 M3560100404 STRIPE 2 33 M3560100703 STRIPE; 100 1 34 M3560100803 STRIPE; 100 1 35 M3560100604 STRIPE 2 36 0600500090 EMBLEM 1 37 0021106015 MACHINE SCREW 2

38 M3552000103 DECAL; OPERATING PROCEDURES ................. 1 ......... M35200010 S/N7400296~

39 MB1552000103 DECAL; CAUTION................................................ 2 ......... B1520010 S/N7400296~

40 C9505300004 DECAL; CA UTION................................................ 1 ......... C90530000 S/N7400296~

41 9039209064 DECAL; START CONT A CT................................... 1 ......... S-4468 S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 89

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

T erms of payment f or 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 f or 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. T o obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b . The list must be typed or computer

generated.

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

the return.

d . The list must reference the sales

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

e. The list must include the name and

phone number of the person requesting the RMA.

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

4. Freight is at the sender’s expense. All

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any material

8 . Such material will be held for 5 working

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 REBA TES

parts must be returned freight prepaid to Multiquip’s designated receiving point.

condition, in the original Multiquip package (if any), and with Muiltiquip part numbers clearly marked.

a . Obsolete parts. (If an item is listed

in the parts price book 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.

received that is not acceptable.

days from notification, pending instructions. If a reply is not received within 5 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 .

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price 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 $20.00 to $50.00 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.

LIMIT A TIONS 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.

LIMIT ATION OF W ARRANTIES

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. A part 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 90 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

NO TE P A GE

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 91

PARTS AND OPERATION 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

SER VICE DEPAR TMENT

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

WARRANTY DEPARTMENT

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

MAIN

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

MUL TIQUIP INC. PARTS DEPARTMENT:

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

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

SERVICE DEPARTMENT:

MULTIQUIP Power WHISPERWATT DCA-100SSJU Parts And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual