Multiquip Mq Power Whisperwatt 60 Hz Generator Dca 100Ssvu Users Manual Rev 0.pmd

MQ Power Whisperwatt 60 Hz Generator DCA-100SSVU Generators_portable_whisperwatt_DCA100SSVU_rev_0_manual_DataId_19082_Version_1

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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL

WHISPERWATTTM SERIES

MODEL DCA-100SSVU
60 Hz GENERATOR
PARTS LIST NO. M3870300704F

Revision #0 (11/05/07)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.

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

HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
800-421-1244
Carson, CA 90746
FAX: 310-632-2656
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
FAX: 800-672-7877
310-537-3700
FAX: 310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX: 310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
FAX: 310-638-8046
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
FAX: 310-638-8046
310-537-3700, EXT. 279

© COPYRIGHT 2007, MULTIQUIP INC.
MQ Power Inc, Ultra-Silent series, and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used,
reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with
permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and
should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are
based on the DCA-100SSVU WHISPERWATT AC Generator. Multiquip Inc. reserves the right to discontinue or change specifications,
design or the information published in this publication at any time without notice and without incurring any obligations.

To find the latest revision of this
publication, visit our website at:
www.mqpower.com

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 3

TABLE OF CONTENTS
MQ POWER DCA-100SSVU
WHISPER
WATTTM GENERATOR
WHISPERW
California Proposition 65 Warning ..................................... 2
Here's How To Get Help .................................................... 3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ............................................... 5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) ........................................... 7
Safety Message Alert Symbols .................................... 8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals ....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ................................................. 21
Engine Operating Panel ............................................. 22-23
Output Terminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
Output Terminal Panel Connections ........................... 30-31
Pre-Setup .................................................................. 32-35
Generator Start-up Procedure (Manual) ..................... 36-37
Generator Start-up Procedure (Auto Mode) .................... 38
Generator Shut-Down Procedure .................................... 39
Maintenance (Engine) ................................................ 40-41
Jacket Water Heater/battery Charger (Option) ................ 42
Maintenance (Trailer) ................................................. 43-46
Trailer Wiring Diagram ..................................................... 47
Generator Wiring Diagram ............................................... 48
Engine Wiring Diagram ................................................... 49
Generator Troubleshooting .............................................. 50
Engine Controller Troubleshooting ................................... 51
Explanation of Code in Remarks Column ....................... 52
Suggested Spare Parts .................................................. 53

COMPONENT DRA
WINGS
DRAWINGS
Generator Assembly .................................................. 54-55
Engine Operating Panel Assembly ............................ 56-57
Control Box Assembly (S/N 7800129 and Below) ..... 58-61
Control Box Assembly (S/N 7800130 and Above) ..... 62-65
Engine and Radiator Assembly ................................. 66-67
Output Terminal Assembly ......................................... 68-69
Actuator Assembly .................................................... 70-71
Battery Assembly ...................................................... 72-73
Muffler Assembly ...................................................... 74-75
Fuel Tank Assembly .................................................. 76-77
Enclosure Assembly ................................................. 78-81
Rubber Seals Assembly ............................................ 82-83
Nameplate and Decals .............................................. 84-87
Terms and Condition of Sale — Parts ............................ 88

NOTE

Specification and part
number are subject to
change without notice.

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

PARTS ORDERING PROCEDURES
When ordering parts,
please supply the following information:
❒
❒
❒
❒
❒
❒
❒

Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
✓ FedEx or UPS Ground
Note: Unless otherwise indicated by customer, all
✓ FedEx or UPS Second Day or Third Day
orders are treated as “Standard Orders”, and will
✓ FedEx or UPS Next Day
ship within 24 hours. We will make every effort to
ship “Air Shipments” the same day that the order is
✓ Federal Express Priority One
received, if prior to 2PM west coast time. “Stock
✓ DHL
Orders” must be so noted on fax or web forms.
✓ Truck

Here’s how to get help...
Please have the model and serial number
on hand when calling.

MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
800-421-1244
FAX: 310-632-2656
Carson, CA 90746
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
FAX: 800-672-7877
310-537-3700
FAX: 310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX: 310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
FAX: 310-638-8046
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
FAX: 310-638-8046
310-537-3700, EXT. 279

Place Your Parts Order Via Web or Fax
For Even More Savings!
(Domestic USA Dealers Only)

Extra Discounts!
All parts orders which include complete part numbers and
are received by our automated web parts order system, or
by fax qualify for the following extra discounts:
Ordered
via
Fax

Standard
orders
3%

Stock orders
($750 list and above)
10%

Web

10%

Special freight allowances
when you order 10 or more
line items via Web or Fax!**
FedEx Ground Service at no charge for freight
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00
list price) do not count towards the 10+ line items.
NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

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

Direct TOLL-FREE access
to our Parts Department:
Toll-free nationwide — 800-427-1244
Toll-free FAX — 800-6-PARTS-7 1
(800/672-7877)

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

DCA-100SSVU — SPECIFICATIONS
Table 1. Generator Specifications
Model

DCA-100SSVU

Type

Revolving field, self ventilated,
open protected type synchronous generator

Armature Connection

Star with Neutral/Zig Zag

Phase

Standby Output

110 KVA (88 KW)

Prime Output

100 KVA (80 KW)

Voltage — 1Ø

120, 127, 139, 240, 254, and 277V

Voltage — 3Ø

208, 220, 240, 416, 440, and 480V

Frequency

60 Hz

S pe e d

1800 r pm

Power Factor

0.8

Dry Weight

4,035 lbs. (1,830 kg.)

Wet Weight

4,675 lbs. (2,120 kg.)

Table 2. Engine Specifications
Model

VOLVO PENTA TAD520GE

Type

4 cycle, water-cooled, direct injection, turbo-charged

No. of Cylinders

4 cylinders

Bore x Stroke

4.25 in. x 5.12 in. (108 mm x 130 mm)

Displacement

290 cu. in. (4.76 liters)

Starting

Electric 12VDC

Coolant Capacity

5.2 gal. (19.7 liters)

Lube Oil Capacity

3.4 gal. (13 liters)

Fuel Type

#2 Diesel Fuel

Fuel Tank Capacity

63 gal. (240 liters)

Fuel Consumption

6.02 gal. (22.8 L)/hr at full load

Battery

12V-128 AH

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

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

Figure 1. Dimensions

TABLE 3. DIMENSIONS
Reference
Letter

Dimension ft. (mm.)

Reference Letter

Dimension ft. (mm.)

30.71 in. (780 mm.)

120.08 in. (3,050 mm.)

30.71 in. (780 mm.)

55.12 in. (1,400 mm.)

41.34 in. (1,050 mm.)

43.31 in. (1,100 mm.)

38.19 in. (970 mm.)

41.34 in. (1,050 mm.)

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 7

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.

NOTE

This Owner's Manual has been
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power Model DCA-100SSVU
Whisperwatt™ Generator.

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

HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
appear throughout this manual, and will be referenced in
conjunction with Safety "Message Alert Symbols".
WARNING - LETHAL EXHAUST GASES
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL

SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING

Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
WARNING - BURN HAZARDS

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

Engine components can generate extreme
heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.

You CAN be injured if you do not follow directions
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!

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

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the engine ON/OFF
switch (MPEC) in the OFF/RESET
position when the generator is not in use.

CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.

NOTE

CAUTION - RESPIRATORY HAZARDS
ALWAYS wear approved respiratory
protection.

CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS wear approved eye and
hearing protection.

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

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

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 9

DCA-100SSVU — RULES FOR SAFE OPERATION
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury 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-100SSVU Whisperwatt™ AC Generator.
General Safety:
■ DO NOT operate or service this
equipment before reading this entire
manual.

■ ALWAYS check the machine for loosened threads or bolts
before starting.
■ NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■ NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■ High Temperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.

The operator MUST BE familiar with proper safety
■ The engine of this generator requires an adequate free
precautions and operations techniques before using
flow of cooling air. NEVER operate the generator in any
generator.
enclosed or narrow area where free flow of the air is
■ This equipment should not be operated by persons under
restricted. If the air flow is
18 years of age.
restricted it will cause serious
damage to the generator or
■ NEVER operate this equipment without proper protective
engine and may cause injury
clothing, shatterproof glasses, steel-toed boots and other
to people. The generator
protective devices required by the job.
engine gives off DEADLY
carbon monoxide gas.
■ DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the influence or
drugs or alcohol.

■ NEVER run engine without air filter. Severe engine damage
may occur.
■ DO NOT leave the generator running in the manual mode
unattended.
■ Refer to the VOLVO Engine Owner's Manual for engine
technical questions or information.
■ ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children.

■ NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
PAGE 10 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — RULES FOR SAFE OPERATION
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.
The following safety recommendations should also be
followed:
■ ALWAYS make sure generator is properly grounded.
■ NEVER use gas piping as an electrical ground.
■ ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and
local codes before operating generator. Severe injury or
DEATH! by electrocution can result from operating an
ungrounded generator.
■ ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
Electrical Safety
■ ALWAYS have a qualified electrician perform the
generator wiring installation.
■ ALWAYS make sure generator installation is accordance
with the National Electrical Code (NEC) and local codes
before operating generator.
■ NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.

DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
terminals, insufficient tightening of the terminal connections
WET
may cause damage to the generator
HANDS
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.

POWER
CORD
(POWER ON)

Backfeed to a utility system can
cause electrocution and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation

■ NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■ ALWAYS make certain that proper extension cord has
been selected for the job. See Table 6.
■ NEVER power cables or cords lay in water.
■ NEVER stand in water while AC power from the generator
is being transfer to a load.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 11

DCA-100SSVU — RULES FOR SAFE OPERATION
Maintenance Safety

Battery Safety

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

Use the following guidelines when handling the battery:

■ NEVER lubricate components or attempt service on a
running machine.
■ ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
■ Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
■ ALWAYS allow the machine a proper amount of time to
cool before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always
replace broken parts.
■ ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
■ Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
■ Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.

■ The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation, always wear safety
glasses.
■ Use well insulated gloves when picking up the battery.
DANGER - EXPLOSION HAZARDS
The risk of an explosion exists when performing service
on the battery. To avoid severe injury or DEATH:
■ DO NOT drop the battery. There
is the possibility of risk that the
battery may explode.
■ DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
■ ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
■ ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
■ ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
■ In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.

■ Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.

PAGE 12 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — RULES FOR SAFE OPERATION
■ The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
To reduce the possibility of an accident while transporting
is not to exceed 15 MPH or less depending on type of
the generator on public roads, always make sure the trailer
terrain.
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically ■ Place chock blocks underneath wheel to prevent rolling,
while parked.
sound.
Towing & Transporting Safety

The following list of safety precautions should be followed ■ Use the trailer’s swivel jack to adjust the trailer height to
when towing your generator:
a level position while parked.
CAUTION - FOLLOW TOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting Department of
Transportation (DOT) Safety Towing Regulations, before
towing your generator.
■ ALWAYS shutdown engine before transporting.

■ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
■ Avoid sharp turns.
■ Trailer should be adjusted to a level position at all times
when towing.
■ Raise and lock trailer wheel stand in up position when
transporting.

■ Tighten both fuel tank caps securely.

■ The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
■ If generator is mounted on a trailer, make sure trailer
is not to exceed 15 MPH or less depending on type of
complies with all local and state safety transportation
terrain.
laws. Follow the listed Towing & Transporting Safety
guidelines for basic towing techniques.
■ Place support blocks underneath the trailer’s bumper to
prevent tipping, while parked.
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle ■ Avoid sharp turns to prevent rolling.
weight rating.”
■ DO NOT transport generator with fuel in tank.
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc. Emergencies
■ Check the tire air pressure on both towing vehicle and ■ ALWAYS know the location of the
nearest fire extinguisher.
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
■ ALWAYS know the location of the
nearest and first aid kit.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS know the location of the
nearest phone or keep a phone on
■ ALWAYS attach trailer’s safety chains to towing vehicle
the job site, in case of emergencies.
properly.
■ ALWAYS make sure the vehicle and trailer directional, ■ ALWAYS have easy access to the phone
numbers of the nearest Ambulance, Doctor
backup, brake, and trailer lights are connected and
and Fire Department. This information will
working properly.
be
invaluable in the case of an emergency.
■ DOT Requirements include the following:
z Connect and test electric brake operation.
z Secure portable power cables in cable tray with tie
wraps.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 13

DCA-100SSVU — GENERATOR DECALS
The DCA-100SSVU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for
operator safety and maintenance information. The illustration below and on the preceding page show the decals as they
appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

Figure 2. Generator Decals
PAGE 14 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 15

DCA-100SSVU — INSTALLATION

Figure 4. Typical Generator Grounding Application

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

DCA-100SSVU — INSTALLATION
Outdoor Installation

Generator Grounding

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

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

The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION - EXHAUST HAZARD
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
Indoor Installation
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.

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 4) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.

NOTE

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

Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 17

DCA-100SSVU — GENERAL INFORMATION
DCA-100SSVU Whisperwatt™ Series Familiarization
Generator
The MQ Power Model DCA-100SSVU is a 80 kW generator
(Figure 5) that is designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other industrial
and construction machinery.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■ Tachometer
■ Water Temperature Gauge
■ Oil Pressure Gauge
■ Charging Ammeter Gauge
■ Fuel Level Gauge
■ Engine Speed Switch
■ Panel Light/Panel Light Switch
■ Auto ON/OFF Engine Controller (MPEC)
Generator Control Panel
The “Generator Control Panel” is provided with the following:
■ Frequency Meter (Hz)
■ AC Ammeter (Amps)
■ AC Voltmeter (Volts)
■ Ammeter Change-Over Switch
■ Voltmeter Change-Over Switch
■ Voltage Regulator
■ 3-Pole, 250 amp Main Circuit Breaker
■ “Control Box” (located behind the Gen. Control Panel)
■ Automatic Voltage Regulator
■ Current Transformer
■ Over-Current Relay
■ Voltage Rectifer
■ Starter Relay
■ Engine Controller (Computer Controlled)
■ Voltage Selector Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
■ Three 120/240V output receptacles (CS-6369), 50A
■ Three auxilliary circuit breakers, 50A
■ Two 120V output receptacles (GFCI), 20A
■ Two GFCI circuit breakers, 20A
■ Five output terminal lugs (3Ø power)
■ Battery Charger (Optional)
■ Water Heater (Optional)

Open Delta Excitation System
The DCA-100SSVU generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
Engine
The DCA-100SSVU is powered by a 6 cylinder, water cooled,
direct injection, turbocharged VOLVO Model PENTA
TAD520GE Diesel Engine. This engine is designed to meet
every performance requirement for the generator. Reference
Table 1 for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Electric Governor System
The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
Extension Cables
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 6) as a guide
for selecting proper extension cable size.

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

DCA-100SSVU — MAJOR COMPONENTS

Table 4. Generator Major Components
ITEM NO.

Figure 5. Major Components

DESCRIPTION

Air Filter Assembly

Voltage Selector Switch Assembly

Air Filter Assembly

Generator Assembly

Jacket Water Heater/BatteryCharger
Assembly (Option)

Output Receptacles Assembly

Engine Assembly

Battery Assembly

Fuel Tank Assembly

Circuit Breaker Assembly

Generator Control Panel Assembly

Engine Control Panel Assembly

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 19

NOTE PAGE

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

DCA-100SSVU — GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel
The definitions below describe the controls and functions of Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
the DCA-100SSVU Generator Control Panel (Figure 6).
1. Frequency Meter – Indicates the output frequency in electronic components required to make the generator
function.
hertz (Hz). Normally 60 Hz.
2.

3.
4.
5.

AC Ammeter – Indicates the amount of current the load The Control Box is equipped with the following major
is drawing from the generator per leg selected by the components:
■ Over-Current Relay
ammeter phase-selector switch.
■ Voltage Rectifer (AVR)
AC Voltmeter – Indicates the output voltage present at ■ Starter Relay
the U,V, and W Output Terminal Lugs.
■ Current Transformer
Voltage Regulator Control – Allows ±15% manual ■ Voltage Selector Switch
adjustment of the generator’s output voltage.
■ Three Phase Circuit Breaker
Ammeter Change-Over Switch – This switch allows
Remember the overcurrent
the AC ammeter to indicate the current flowing to the
relay monitors the current
NOTE
load connected to any phase of the output terminals, or
flowing from the U,V, and W
to be switched off. This switch does not effect the
Output Terminal Lugs to the
generator output in any fashion, it is for current reading
load.
only.
In the event of a short circuit or over current condition, it will
Voltmeter Change-Over Switch – This switch allows automatically trip the 250 amp main breaker.
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to To restore power to the Output Terminal Panel, press the
reset button on the overcurrent relay and place the main
be switched off.
circuit breaker in the closed position (ON).
Main Circuit Breaker – This three-pole, 250A main
breaker is provided to protect the the U,V, and W Output
Terminal Lugs from overload.

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

DCA-100SSVU — ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

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

DCA-100SSVU — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-100SSVU Engine Operating Panel (Figure 7).
1. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 44 to 73 psi. (303~503
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
4. Water Temperature Gauge – During normal operation
this gauge be should read between 165° and 203°F.
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
8. Engine Speed Switch – This switch controls the speed
of the engine (low/high).
9.

If the engine does not engage (start) by the third attempt,
the engine will be shutdown by the engine controller’s Over
Crank Protection mode. If the engine engages at a speed
(RPM's) that is not safe, the controller will shutdown the
engine by initializing the Over Speed Protection mode.
Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup. These conditions
can be observed by monitoring the LED status indicators on
the front of the controller module.
A. MPEC Control Switch – This switch controls the
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.
If the generator is to be connected to a building’s AC
power source via an automatic transfer switch
(isolation), place the switch in the AUTO position. In
this position, should an outage occur, the automatic
transfer switch (ATS) will start the generator
automatically via the generator’s auto-start contacts
connected to the ATS’s start contacts. Please refer to
your ATS installation manual for further instructions for
the correct installation of the auto-start contacts of the
generator to the ATS.
B. Low Oil Pressure – Indicates the engine pressure has
fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a major fault.

Auto On/Off Engine Controller (MPEC) –
This controller has a vertical row of status LED's (inset),
that when lit, indicate that an engine malfunction (fault) C. High Coolant Temperature – Indicates the engine
has been detected. When a fault has been detected the
temperature has exceeded 239°F. The engine
engine controller will evaluate the fault and all major
temperature is detected using variable resistive values
faults will shutdown the generator. During cranking
from the temperature sending unit. This is considered
cycle , The MPEC will attempt to crank the engine for
a major fault.
10 seconds before disengaging.
D. Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration. This is considered a major
fault.
E. Overspeed Shutdown – Indicates the engine is running
at an unsafe speed. This is considered a major fault.
F.

Engine Running – Indicates that engine is running at
a safe operating speed.
1

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

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel

Output Terminal Familiarization

The Output Terminal Panel (Figure 8) shown below is located The “Output Terminal Panel ” (Figure 8) is provided with the
on the right-hand side (left from control panel) of the generator. following:
Lift up on the cover to gain access to receptacles and terminal ■ Three (3) 120/240V output receptacles @ 50 amp
lugs.
■ Three (3) Circuit Breakers @ 50 amps
NOTE

■ Two (2) 120V GFCI receptacles @ 20 amp
Terminal legs “O” and “Ground”
are considered bonded grounds. ■ Two (2) GFCI Circuit Breakers @ 20 amps
■ Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

Figure 8. Output Terminal Panel
PAGE 24 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
100 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) of both
GFCI receptacles is dependent on the load requirements of
the U, V, and W output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the Test Button (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.

Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
Output Terminal Lugs.
Turn the voltage regulator control knob (Figure 11) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob counterclockwise will decrease the voltage.

Figure 11. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire Hookup Panel)
The Output Terminal Lugs are protected by a plastic face
plate cover (Figure 12). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 10) provided on the output
terminal panel.These receptacles can only be accessed
when the voltage selector switch is placed in the singlephase 240/120 position.

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Figure 10. 120/240V Twist-Lock
Auxiliary Receptacles
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 25

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
Loads can be connected to the generator by the Ouput An over current relay (Figure 14) is connected to the main
Terminal Lugs or the convenience receptacles (Figure 13). circuit breaker. In the event of an overload, both the circuit
Make sure to read the operation manual before attempting breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over curto connect a load to the generator.
rent relay must be pressed. The over current relay is loTo protect the output terminals from overload, a
cated in the control box.
3-pole, 250A main circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
Connecting Loads

Figure 14. Over Current Relay

Figure 13. Connecting Loads

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

DCA-100SSVU — LOAD APPLICATION
Single Phase Load

Three Phase Load

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.

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

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
If wattage is not given on the
equipment's name plate,
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

NOTE

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

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

The power factor of this generator is 0.8. See Table 5 below
An inadequate size connecting cable which cannot carry the
when connecting loads.
required load can cause a voltage drop which can burn out
Table 5. Power Factor By Load
the appliance or tool and overheat the cable. See Table 6.
Type Of Load

Power Factor

Single-phase induction motors

0.4 - 0.75

Electric heaters, incandescent
lamps

1 .0

Fluorescent lamps, mercury lamps

0.4 - 0.9

Electronic devices, communication
equipment

1 .0

Common power tools

0.8

incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
■ When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
■ When connecting an electric drill or other power tools,

pay close attention to the required starting current
capacity.

Table 6. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Current in
Amperes At 100
Volts

■ When connecting a resistance load such as an

Maximum Allowable Cable Length

At 200
Volts

#10 Wire

#12 Wire

#14 Wire

#16 Wire

2.5

3 00

600

1000 ft.

600 ft.

375 ft.

250 ft.

600

1200

500 ft.

300 ft.

200 ft.

125 ft.

7.5

900

1800

350 ft.

200 ft.

125 ft.

100 ft.

1200

2400

250 ft.

150 ft.

100 ft.

1800

3600

150 ft.

100 ft.

65 ft.

2400

4800

125 ft.

75 ft.

50 ft.

When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any building’s electrical
system, a licensed electrician must install an isolation
(transfer) switch. Serious damage to the building’s
electrical system may occur without this transfer switch.

CAUTION: Equipment damage can result from low voltage.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 27

DCA-100SSVU — GENERATOR OUTPUTS
Voltage Selector Switch
Generator Amperage
The voltage selector switch (Figure 16) is located above Table 8 describes the generator’s current output capability
the output terminal panel’s Hard Wire Hook-up Panel. It for both 1Ø-phase and 3Ø phase applications.
has been provided for ease of voltage selection.
Table 8. Generator Maximum Amps

Figure 16. Voltage Selector Switch
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and load from being switched while the engine
is running. To lock the voltage selector switch, press and
hold the red button located at the bottom of the switch.
CAUTION - CHANGING VOLTAGES
NEVER change the position of the voltage selector switch
while the engine is running. ALWAYS place circuit breaker
in the open position before selecting voltage.
Generator Output Voltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 16). To obtain some of
the voltages as listed in Table 7 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.

Model

DCA100SSVU

Rated Voltage

Maximum Amps

Single Phase
120 Volt

222.2 amps (4 wire)

Single Phase
240 Volt

111.1 amps (4 wire)

Three Phase
240 Volt

241 amps

Three Phase
480 Volt

120 amps

GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.
Tables 9 and 10 show what amount of current is available at
the GFCI receptacles when the output terminals and twist
lock receptacles are in use. Be careful that your load does
not to exceed the available current capability at the receptacles.
Table 9. 1Ø GFCI Receptacle Load Capability
KW in Use
Twist-Lock (CS6369)
1Ø 240/120V
57.7
5 6 .5
5 5 .3
54.1
5 2 .9

Available Load
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle

Table 10. 3Ø GFCI Receptacle Load Capability
Table 7. Voltages Available

KVA in Use
(UVWO Terminals)

Three Phase
(Switchable)

208V

220V

240V

416V

440V

4 8 0V

Single Phase
(Switchable)

120V

127V

1 3 9V

240V

254V

277V

3Ø 240/480V
100
95.8
91.7
87.5
83.4

Available Load
Current (Amps)
GFCI Duplex NEMA
5-20R 120V
0
5 amps per receptacle
10 amps per receptacle
15 amps per receptacle
20 amps per receptacle

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

DCA-100SSVU — GAUGE READING
How to Read the Output Terminal Gauges.
The gauges and selector switches on the control panel
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied at the
Output terminals lugs.
Before taking a reading off either gauge, set the Voltage
Selector Switch (Figure 17) to the position which produces
the required voltage (For example, for 3Ø 240V,
choose the center 3Ø 240/
139V position on the voltage selector switch.)

Reading Amperage
To determine the amperage at a terminal lug, set the
AC Ammeter Change-Over Switch to the appropriate
setting (Figure 20) to activate the AC Ammeter Gauge
(Figure 21) and read the available amperage at the terminal
lug.
For example, to measure the amperage at the U
terminal lug, set the AC Ammeter Change-Over Switch to
U and read the AC Ammeter Gauge.

Figure 17. Voltage
Selector Switch 240/
139V Three Phase
Position
Figure 20. AC Ammeter
Change-Over Switch

NOTE

For 3Ø 208V/1Ø,120V, place
the Voltage Selector Switch
in the 3 Phase 340/139
position.

Reading Voltage
To determine the voltage between two terminal lugs, set the
AC Voltmeter Change-Over Switch to the appropriate
setting (Figure 18) to activate the AC Voltmeter Gauge
(Figure 19) and read the available voltage between the two
lugs.
For example, to measure the voltage between the W and U
terminal lugs, set the AC Voltmeter Change-Over Switch
to W-U and read the AC Voltmeter Gauge.

NOTE

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

The ammeter gauge will only
show a reading when the
Output Terminal Lugs are
connected to a load and in use.

Figure 18. AC Voltmeter Figure 19. AC Voltmeter Gauge
Change-Over Switch
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 29

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø 208V/1Ø120V Output Terminal Lug Voltages
Various output voltages can be obtained using the Output 1. Place the voltage selector switch in the 3Ø 240/139
Terminal Lugs.. The voltages at the terminals are depenposition as shown in Figure 25.
dent on the position of the Voltage Selector Switch and the
Use this position for
adjustment of the Voltage Regulator Control Knob.
3Ø-208 or 1Ø120V.
Remember the voltage selector switch determines the range
of the output voltage. The voltage regulator (VR) allows the
user to increase or decrease the selected voltage.
3Ø 240/139 Output Terminal Lug Voltages

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

1. Place the voltage selector switch in the 3Ø 240/139
position as shown in (Figure 22).

2. Connect the load wires to the Output Terminal Lugs as
shown in Figure 26.

Figure 22. Voltage Selector Switch 240/139V
Three-Phase Position
2. Connect the load wires to the Output Terminal Lugs as
shown in (Figure 23).

Figure 26. Output Terminal Lugs
3Ø-208V/120V Connections
3. Turn the voltage regulator knob (Figure 25) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

Figure 23. Output Terminal Lugs
240/139V Three Phase Connections
3. Turn the voltage regulator knob (Figure 24) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output.

NOTE

To achieve a 3Ø 208V output
the voltage selector switch
must be in the 3Ø-240/139
position and the voltage
regulator must be adjusted to
208V.

Figure 24. Voltage Regulator Knob (139V/240V)
PAGE 30 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø 480/277 Output Terminal Lug Voltages
1Ø 240V/120V Output Terminal Lug Voltages
1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 27.
position as shown in Figure 29.

Figure 27. Voltage Selector Switch 480/277V
Three-Phase Position

Figure 29. Voltage Selector Switch 240/120V
Single-Phase Position

2. Connect the load wires to the Output Terminal Lugs as 2. Connect the load wires to the Output Terminal Lugs as
shown in Figure 28.
shown in (Figure 30).

BLACK

BLUE

RED

WHITE

GREEN

BLACK

BLUE

RED

WHITE

GREEN

NOT USED
480V

240V

277V

480V

120V

GROUND CONNECTION
MUST BE USED
AT ALL TIMES

480V

277V
277V

Figure 28. Output Terminal Lugs
480/277V Three Phase Connections

120V

Figure 30. Output Terminal Lugs
1Ø-240V/120V Connections

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

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 31

DCA-100SSVU — SETUP
Fuel Check

Circuit Breakers
To protect the generator from an overload, a 3-pole, 250 amp,
main circuit breaker is provided to protect the U,V, and W
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 load circuit
breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.

DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.

Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 9 for proper
Refilling the Fuel System
selection of engine oil.
CAUTION - REFUELING THE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
Figure 30. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Volvo Engine Owner's Manual. Oil should be warm
before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
■
■
■
■

API Service Classification CC/SC
API Service Classification CC/SD
API Service Classification CC/SE
API Service Classification CC/SF

This generator has an internal fuel tank located inside the
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31). ALWAYS fill the fuel tanks with clean
fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their
capacities.
Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.

Figure 31. Internal Fuel Tank System

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

DCA-100SSVU — SETUP
Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

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

Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
CAUTION - REFUELING THE GENERATOR

ALWAYS place trailer on firm level ground before refueling
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
Figure 33. Fueling the Generator

NEVER overfill fuel tank – It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait for
fuel to rise in filler neck (Figure 34).

Figure 32. Only Fill on Level Ground

NOTE

ONLY! use #2 diesel fuel when
refueling.
Figure 34. Full Fuel Tank
CAUTION - REFUELING THE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 35).

Figure 35. Fuel Expansion
1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 33

DCA-100SSVU — SETUP
Coolant (Antifreeze/Summer Coolant/Water)
VOLVO recommends VOLVO antifreeze/summer coolant for
use in their engines, which can be purchased in concentrate
(and mixed with 50% demineralized water) or pre-diluted.
See the VOLVO Engine Owner's Manual for further details.

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

WARNING - BURN HAZARDS

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

If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which
can cause severe burns.

Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the VOLVO
Engine Owner's Manual.

Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove The fan belt tension is proper if the fan belt bends 10 to 15
the radiator cap until the unit has completely cooled. See mm (Figure 36) when depressed with the thumb as shown
Table 12 for engine, radiator, and recovery tank coolant below.
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.

Table 12. Coolant Capacity
Engine and Radiator

5.2 Gal. (19.7 liters)

Reserve Tank

2 Quar ts (1.9 liters)

Operation Freezing Weather

CAUTION - ROTATING PARTS

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze
Operating Temperatures
Vol %
Anti-Freeze
50

NOTE

Figure 36. Fan Belt Tension

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

Freezing Point
°C

°F

-37

-34

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

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

DCA-100SSVU — SETUP
When connecting battery do the following:

Battery

This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
Always maintain battery fluid level between the specified
the MANUAL position. ALWAYS make sure that the MPEC
marks. Battery life will be shortened, if the fluid level are not
Control Switch is in the OFF/RESET position when
properly maintained. Add only distilled water when
replenishment is necessary.
connecting the battery.
DO NOT over fill. Check to see whether the battery cables 2. Place a small amount of battery terminal treatment
are loose. Poor contact may result in poor starting or
compound around both battery terminals. This will ensure
malfunctions. Always keep the terminals firmly tightened.
a good connection and will help prevent corrosion around
Coating the terminals with an approved battery terminal
the battery terminals.
treatment compound. Replace battery with only
recommended type battery. The battery type used in this
If the battery cable is connected
generator is BCI Group 27.
incorrectly, electrical damage to the
NOTE
The battery is sufficiently charged if the specific gravity of
generator will occur. Pay close
the battery fluid is 1.28 (at 68° F). If the specific gravity
attention to the polarity of the
should fall to 1.245 or lower, it indicates that the battery is
battery when connecting the
dead and needs to be recharged or replaced.
battery.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
CAUTION - BATTERY SERVICING SAFETY
Battery Cable Installation
Inadequate battery connections may cause poor starting
ALWAYS be sure the battery cables (Figure 37) are properly
of the generator, and create other malfunctions.
connected to the battery terminals as shown below. The Red
Cable is connected to the positive terminal of the battery,
and the Black Cable is connected to the negative terminal Alternator
of the battery.
The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
CAUTION - BATTERY SERVICING SAFETY
in short circuit instantaneously resulting the alternator failure.

ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.

DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.

Figure 37. Battery Connections

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

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 35

DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)
Before Starting
CAUTION - LETHAL EXHAUST HAZARD

Manual Start-up Procedure
1. Place the engine speed switch (Figure 41) in the “LOW ”
(down) position.

The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING - STARTING THE GENERATOR

NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.

Figure 41. Engine Speed Switch (Low)

1. Place the main, G.F.C.I., and aux. circuit breakers 2. Once the engine glow plugs have been warmed, place
the MPEC Control Switch in the MANUAL position to
(Figure 38) in the OFF position prior to starting the engine.
start the engine (Figure 42).

Figure 42. MPEC Control Switch
(Manual Position)
Figure 38. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Make sure the the voltage change-over board has
been configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
4. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
5. Close all engine enclosure doors (Figure 39).

Figure 39. Engine Enclosure Doors

3. Once the engine starts, let it engine run for 1-2 minutes.
Listen for any abnormal noises. If any abnormalities
exists shutdown the engine and correct the problem.
If the engine is running smoothly, place the engine
speed switch (Figure 43) in the “HIGH” (up) position.

Figure 43. Engine Speed Switch (High)

4. Verify that the Engine Running
status LED on the MPEC unit
(Figure 44) is ON (lit) after the
engine has been started.

Figure 44. Engine Running LED (ON)

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

DCA-100SSVU — GENERATOR START-UP PROCEDURE (MANUAL)
5. The generator's frequency meter (Figure 45) should be
displaying the 60 cycle output frequency in HERTZ.

9. The coolant temperature gauge
(Figure 50) will indicate the
coolant temperature. Under
normal operating conditions the
coolant temperature should be
between 165~203 °F (74~95 °C),
Green Zone.
Figure 50. Coolant
Temperature Gauge

Figure 45. Frequency Meter (Hz)
6. The generator's AC-voltmeter (Figure 47) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 47) to increase or decrease the
desired voltage.

10. The tachometer gauge (Figure 51)
will indicate the speed of the engine
when the generator is operating.
Under normal operating conditions
this speed is approximately 1800
RPM’s.
Figure 51. Engine
Tachometer Gauge
11. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 52).

Figure 46. Voltmeter

Figure 47. Voltage Adjust Control Knob
7. The ammeter (Figure 48) will
indicate zero amps with no load
applied. When a load is applied, the
ammeter will indicate the amount of
current that the load is drawing from
the generator.
Figure 48. Ammeter
(No Load)
8. The engine oil pressure gauge
(Figure 49) will indicate the oil
pressure of the engine. Under
normal operating conditions the oil
pressure is approximately 44 to 73
psi. (303~503 kPa). When starting
the genera

Figure 52. Main, Aux. and GFCI
Circuit Breakers (ON)
12. Observe the generator's ammeter
(Figure 53) and verify it reads the
anticipated amount of current with
respect to the load. The ammeter
will only display a current reading if
a load is in use.
Figure 53. Ammeter
(Load)
13. The generator will run until manually stopped or an
abnormal condition occurs.

Figure 49. Oil
Pressure Gauge

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

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

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

DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to the
building’s electrical system may occur
without this transfer switch.
CAUTION - BACKUP GENERATOR USE
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.

NOTE

When the generator is set in the
AUTO mode, the generator will
automically start in the event of
comercial power falling below a
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.

1. Perform steps 1 through 5 in the Before Starting section.
2. Place the engine speed switch (Figure 54) in the HIGH
position

Figure 54. Engine Speed Switch (High)
3. Place the MPEC Control Switch (Figure 55) in the AUTO
position

Figure 55. MPEC Control Switch (AUTO)
4. Continue operating the generator as outlined in the
Manual Start-up Procedure (start at step 5).

WARNING - AUTO MODE MAINTENANCE
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.

CAUTION - ENGINE SPEED SWITCH
The Engine Speed Switch must be set to the “High”
position when running in the Auto-Start mode. Failing to
set the switch in the proper position can result in damage
to your generator when it turns on.

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

DCA-100SSVU — GENERATOR SHUT-DOWN PROCEDURES
WARNING - SHUTTING DOWN THE GENERATOR
NEVER stop the engine suddenly except in an emergency.
Normal Shutdown Procedure
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 38 to the OFF position.
2. Place the engine speed switch (Figure 56) in the “LOW ”
(down) position.

Emergency Shutdown Procedure
1. Place the MPEC Control Switch switch (Figure 57) to
the OFF/RESET position.
2. To shut-down the engine in the event of an emergency,
switch the MAIN, GFCI and LOAD (Figure 38) circuit
breakers to OFF position.

Figure 56. Engine Speed Switch (Low)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 57) to the
OFF/RESET position.

Figure 57. MPEC Control Switch (Off/Reset)
5. Verify that the all status LED on the MPEC display
are OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occured during operation.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 39

DCA-100SSVU — MAINTENANCE
10 Hrs
DAILY

TABLE 14. INSPECTION/MAINTENANCE
Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

Check for Leaks

Check for Loosening of Par ts

Replace Engine Oil and Filter *

500 Hrs

Check Fuel Filter/Water Seperator Bowl

Clean Unit, Inside and Outside

Change Fuel Filter

Clean Radiator and Check Coolant Protection Level*2

Replace Air Filter Element *

1000 Hrs

Clean Air Filter

ENGINE

250 Hrs

Check all Hoses and Clamps *

X
4

Clean Inside of Fuel Tank

Measure Insulation Resistance Over 3M ohms

GENERATOR
Check Rotor Rear Suppor t Bearing

*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Add "Supplemental Coolant Addatives (SCA'S)" to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the bloby hose is at least a 1/2 inch per foot, with
no sags or dips that could collect moisture and/or oil.

General Inspection

Service Daily

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

If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.

Air Cleaner

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

Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator is attached to the air cleaner. When the air
cleaner element is clogged, air intake restriction becomes
greater and the dust indicator signal shows RED meaning
the element needs changing or service. After changing the
air element, press the dust indicator button to reset the
indicator.

Fuel Addition

Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.

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

DCA-100SSVU — MAINTENANCE
Flushing Out Radiator and Replacing Coolant

Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure. See the VOLVO Engine
Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed. This
unit is equipped with an automatic air bleeding system.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 31.
Replacing Oil Filter
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in gasoline.
Securely fasten the fuel strainer cap so that fuel will not
leak. Check the fuel strainer every 200 hours of operation or
once a month.
Replacing Fuel Filter

Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open the
radiator cap while draining. Remove the overflow tank
and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO NOT
clean radiator core with any objects, such as a
screwdriver.
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufaturer.
Close radiator cap tightly.
WARNING - BURN HAZARDS
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
Generator Storage
For longe term storage of the generator the following is
recommended:
Fill the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire generator, internal and external.

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

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

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

Make sure engine coolant is at proper level.

Vent any air.

Disconnect the battery.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 41

DCA-100SSVU — MAINTENANCE
Jacket Water Heater and Internal Battery Charger
120 VAC Input Receptacles (OPTIONAL)
This generator can be optionally equipped with two 120 VAC,
20 amp input receptacles located on the output terminal
panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 58). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).

If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.

NOTE

To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger.

When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater simply apply power to
the jacket water heater receptacle via commercial power
using an power cord of adequate size.

Figure 56. Battery Charger &
Jacket Water Heater Power Connections

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

DCA-100SSVU — TRAILER MAINTENANCE
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
This section is intended to provide the user with generic
(175,185,205, etc.). The tire diameter must match the
trailer service and maintenance information. The service and
diameter of the tire rim.
maintenance guidelines referenced in this section refer to a
wide range of trailers.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and 10. Wheel Hub - The wheel hub is connected to the trailer’s
damage to the equipment.
axle.
The definitions below describe some of the major components 11. Tire Rim - Tires mounted on a tire rim. The tire rim must
of a typical trailer that would be used with the DCA-100SSVU
match the size of the tire.
Whisperwatt™ Generator.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
1. Fuel Cell - Provides an adequate amount of fuel for the
Always use a torque wrench to tighten down the lug
equipment in use. Fuel cells must be empty when transnuts. See Table 16 and Figure 59 for lug nut tightening
porting equipment.
and sequence.
2. Braking System - System employed in stopping the 13. Axle - Indicates the maximum weight the axle can suptrailer. Typical braking systems are electric, surge, hyport in pounds, and the diameter of the axle expressed
draulic, hydraulic-surge and air.
in inches. Please note that some trailers have a double
Trailer Maintenance

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
14.
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
5. Frame Width - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.

axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.
Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 43

DCA-100SSVU — TRAILER MAINTENANCE
Brakes
Trailer brakes should be inspected the first 200 miles 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.
Figure 59 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 and Table 15 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
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. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
8. Repeat steps 1 through 7 on the remaining brakes.

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

Figure 59. Hydraulic Brake Components
Actuator
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the surge or push of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
Periodically check and test the surge “actuator” to make
sure that it is functioning correctly. Never use an undersize
actuator.

Table 15. Hydraulic Brake Troubleshooting
Symptom

Possible Cause

Solution

No Brakes

Brake line broken or kinked?

Repair or replace.

Brake lining glazed?

Reburnish or replace.

Weak Brakes or Brakes Pull to
One Side

Trailer overloaded?

Correct weight.

Brake drums scored or grooved?

Machine or replace.

Tire pressure correct?

Inflate all tires equally.

Tires unmatched on the same axle?

Match tires.

Brake components loose, bent or broken?

Replace components.

Locking Brakes
Brake drums out-of-round?

Replace.

System lubricated?

Lubricate.

Noisy Brakes
Brake components correct?

Replace and correct.

Brake lining thickness incorrect or not
adjusted correctly?

Install new shoes and
linings.

Enough brake fluid or correct fluid?

Replace rubber par ts
fill with dot 4 fluid.

Dragging Brakes

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

DCA-100SSVU — TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION - EYESIGHT HAZARD

Suspension
The leaf suspension springs and associated components
(Figure 60) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.

ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRING TRAILER WHEELS
DO NOT attempt to repair or modify a wheel. DO NOT
install in inner tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot!. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.

Figure 60. Major Suspension Components

Table 17. Suspension Torque Requirements
Item

Torque (Ft.-Lbs.)

3/8" U-BOLT

MIN-30 MAX-35

7/16" U-BOLT

MIN-45 MAX-60

1/2" U-BOLT

MIN-45 MAX-60

SHACKLE BOLT
SPRING EYE BOLT

SHOULDER TYPE
SHACKLE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.

MIN-30 MAX-50

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 45

DCA-100SSVU — TRAILER MAINTENANCE
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 61). DO NOT
torque the wheel lug nuts all the way down. Tighten each
lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size

First Pass
FT-LBS

Second Pass
FT-LBS

Third Pass
FT-LBS

12"

20-25

35-40

50-65

13"

20-25

35-40

50-65

14"

20-25

50-60

90-120

15"

20-25

50-60

90-120

16"

20-25

50-60

90-120

Figure 61. Wheel Lug Nuts
Tightening Sequence

NOTE

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

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

DCA-100SSVU — TRAILER WIRING DIAGRAM

Figure 62. Trailer/Towing Vehicle Wiring Diagram

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 47

DCA-100SSVU — GENERATOR WIRING DIAGRAM

Figure 63. Generator Wiring Diagram
PAGE 48 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — ENGINE WIRING DIAGRAM

Figure 64. Engine Wiring Diagram

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 49

DCA-100SSVU — TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.

TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

POSSIBLE PROBLEM

SOLUTION

AC Voltmeter defective?

Check output voltage using a voltmeter.

Is wiring connection loose?

Check wiring and repair.

Is AVR defective?

Replace if necessary.

Defective Rotating Rectifier?

Check and replace.

Defective Exciter Field?

Check for 17.3 ohms across J & K on CN1

Is engine speed correct?

Turn engine throttle lever to "High".

Is wiring connections loose?

Check wiring and repair.

Defective AVR?

Replace if necessary.

Is wiring connections loose?

Check wiring and repair.

Defective AVR?

Replace if necessary.

Shor t Circuit in load?

Check load and repair.

Over current?

Confirm load requirements and reduce.

Defective circuit breaker?

Check and replace.

Over current Relay actuated?

Confirm load requirement and replace.

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

DCA-100SSVU — TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor
Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)
SYMPTOM

Low oil pressure light is
on.

POSSIBLE PROBLEM
Low oil level?

Fill oil level.

Oil pressure sending unit failure?

Replace oil pressure sending unit.

Time delay malfuntion in Controller?

Refer to dealer.

Wire shor ted?

Inspect/repair wire.

Low coolant level?
Low coolant level light is
Sending unit failure?
on. (Optionally Installed)
Low battery voltage?

High coolant temper ture
light is on.

SOLUTION

Fill coolant level.
Replace sending unit.
Replace/charge battery.

Fan belt tension incorrect?

Tighten/replace fan belt.

Air flow is not circulation through radiator?

Clean/repair radiator grill.

Doors open?

Close doors.

Exhaust leaking?

Replace/repair gaskets or faulty par t.

Generator being overloaded?

Check/reduce load.

Thermostat failure?

Replace thermostat.

Air intake blocked?

Clear all air intakes.

Temperature switch failure?

Replace temperature switch.

No or low Fuel?

Fill fuel level.

Controller needs to be calibrated?

Refer to dealer.

RPM engine speed too high?

Adjust RPM.

Governor actuator needs to be adjusted?

Adjust governor actuator.

Governor controller needs to be adjusted?

Adjust governor controller.

Engine Controller needs to be calibrated?

Refer to dealer.

Magnetic pick up out of adjustment?

Adjust magnetic pick up.

Magnetic pick up dir ty?

Clean magnetic pick up.

Overcrank light is on.

Overspeed light is on.

Loss of MPU light(s) or
on.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 51

DCA-100SSVU — EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and remarks
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are
subject to change without notice. Multiquip does not
guarantee the availibility of the parts listed.

PART NO. PART NAME
QTY.
12345
BOLT ....................... 1 ....
WASHER, 1/4 IN. ...........
12347
WASHER, 3/8 IN. .... 1 ....
12348
HOSE .................... A/R ..
12349
BEARING ................ 1 ....

*
*

REMARKS
INCLUDES ITEMS W/
NOT SOLD SEPARATELY
MQ-45T ONLY
MAKE LOCALLY
S/N 2345B AND ABOVE

A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed to
describe the item can also be shown.

Assembly/Kit - All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:

NO. Column

“INCLUDES ITEMS W/(unique symbol)”

Unique Symbols - All items with same unique symbol
( , #, +, %, or >) in the number column belong to the same
assembly or kit, which is indicated by a note in the “Remarks”
column.

Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.

N
OTE

Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.

REMARKS Column

Sample Parts List:
NO.
1
2
2
3
4

QTY. Column

When ordering a part that has more
than one item number listed, check
the remarks column for help in
determining the proper part to order.

PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.

Serial Number Break - Used to list an effective serial number
range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”

Specific Model Number Use - Indicates that the part is used
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”

“Make/Obtain Locally” - Indicates that the part can be
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
“Not Sold Separately” - Indicates that an item cannot be
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.

PAGE 52 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU — SUGGESTED SPARE PARTS
DCA-100SSVU WHISPER WATTGENRATOR
W/VOLVO PENTA TAD520GE DIESEL ENGINE
1 TO 3 UNITS
Qty.
P/N
Description
1 ......... V20412278 .......... HOSE, RADIATOR UPPER
1 ......... V20412279 .......... HOSE, RADIATOR LOWER
1 ......... V20412329 .......... RADIATOR CAP
1 ......... 0605505070 ........ FUEL CAP
1 ......... V20405794 .......... ALTERNATOR 12 VDC
2 ......... V978515 .............. V-BELT, ALTERNATOR
2 ......... V978750 .............. V-BELT, FUEL PUMP
1 ......... V20405779 .......... MONITOR, OIL PRESSURE
1 ......... V20405778 .......... SENSOR, OIL PRESSURE
1 ......... V20543720 .......... TEMP SENSOR UNIT
1 ......... V20412270 .......... SENSOR, TEMPERATURE
6 ......... V20549350 .......... FILTER, FUEL CARTRIDGE
6 ......... V8159975 ............ FILTER, WATER SEPARATOR
6 ......... V3831236 ............ FILTER, OIL CARTRIDGE
3 ......... V3840033 ............ FILTER, AIR (ELEMENT)
1 ......... 0601808803 ........ CIRCUIT BREAKER, 1P, 120V @ 20A
1 ......... 0601808804 ........ CIRCUIT BREAKER, 2P, 250V @ 50A
2 ......... LY2DUS12VDC .. RELAY

NOTE

Part number on this Suggested Spare Parts list
may supercede/replace the P/N shown in the text
pages of this book.

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 53

DCA-100SSVU — GENERATOR ASSY.
GENERATOR ASSY.

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

DCA-100SSVU — GENERATOR ASSY.
GENERATOR ASSY.
NO
1
1-1
*
1-2
*
1-3
*
1-4
*
1-5
*
1-6
*
1-7
*
1-8
*
1-9
*
1-10
*
1-11
*
1-12
*
1-13
*
1-14
*
1-15
*
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A

PART NO
C0110000202
8101070033
8101611004
8101015003
0012110030
0042510000
8101026013
0601821349
0601822601
8001020004
8001020504
0010110020
0040010000
0601000209
0071906311
C0130200003
0845041804
8101315202
8101350013
0012110070
0042610000
0041210000
0010110035
0040010000
0041210000
8101310014
8131312014
8101333003
0017106012
8101333003
0010106030
0040006000
0041206000
M2163400003
0012110040
0042610000
0070506306
0012810030
0012810030
8111332014
0600815000
0605000061
0030016000
0040016000

PART NAME
QTY.
REMARK
ROTOR ASSY. ........................... 1 .................... INCLUDES ITEMS W/
*
FIELD ASSY.
1
FAN
1
COUPLING DISK
5
BALANCING PLATE .................. 1 .................... PURCHASE ITEM 1-14 AS A SET
HEX HEAD BOLT
8
WASHER, LOCK
8
SET PLATE, RECTIFIER ........... 1 .................... PURCHASE ITEM 1-14 AS A SET
RECTIFIER, PT 3610
2
SURGE ABSORBER
1
INSULATOR WASHER
1
INSULATOR WASHER
1
HEX HEAD BOLT
4
WASHER, LOCK
4
BALANCING WEIGHT KIT
1
BEARING, 6311DDU C3
1
STATOR ASSY.
1
GROMMET
2
END BRACKET
1
FIELD ASSY. EXCITER
1
HEX HEAD BOLT
4
WASHER, LOCK
4
WASHER, FLAT
4
HEX HEAD BOLT
6
SPRING WASHER
6
WASHER, FLAT
6
COVER, BEARING
1
GASKET, BEARING
1
COVER, END BRACKET
1
HEX HEAD BOLT
10
COVER, END BRACKET
1
HEX HEAD BOLT
2
WASHER, LOCK
2
PLAIN WASHER
2
COUPLING RING
1
HEX HEAD BOLT
8
WASHER, LOCK
8
BEARING
1
HEX HEAD BOLT
8
HEX HEAD BOLT
12
COVER, FAN
1
NUT
1
RUBBER SUSPENSION
2
HEX NUT
2
WASHER, LOCK
2

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 55

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.

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

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

PART NO
0602202545
0601831340
0601831395
0602120096
0602122097
0602123094
0602121080
0602125090
0601810141
0601831330
M3351100004
0017106040
0027105010
M3223100004
0027105010
M3357200702
M3357201412
0601802149
0601806671

PART NAME
QTY.
REMARKS
CONTROLLER, ECU-9988N
1
SWITCH
1
ENGINE SPEED SWITCH
1
TACHOMETER
1
OIL PRESSURE GAUGE
1
WATER TEMPERATURE GAUGE
1
CHARGING AMMETER
1
FUEL GAUGE
1
PANEL LIGHT
1
SWITCH, PANEL LIGHT
1
ENGINE OPERATING PANEL ........................... 1 ............. S/N 7800130 AND ABOVE
HEX HEAD BOLT .............................................. 2 ............. S/N 7800130 AND ABOVE
MACHINE SCREW ........................................... 4 ............. S/N 7800130 AND ABOVE
STOPPER ......................................................... 1 ............. S/N 7800130 AND ABOVE
MACHINE SCREW ........................................... 2 ............. S/N 7800130 AND ABOVE
WIRE HARNESS, ENGINE ............................... 1 ............. S/N 7800001~7800129
WIRE HARNESS, ENGINE ............................... 1 ............. S/N 7800130 AND ABOVE
FUSE, 10A
1
FUSE, 15A
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 57

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (S/N 7800001~7800129)

PAGE 58 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (S/N 7800001~7800129)
NO
PART NO
PART NAME
QTY.
REMARKS
1
M321300602
CONTROL BOX ............................................. 1 ................. S/N 7800001~7800129
2
0601808822
CIRCUIT BREAKER, 3P 250A
1
3
0021005080
MACHINE SCREW
4
4
0601823863
RELAY UNIT
2
5
0027104016
MACHINE SCREW
4
6
0601820671
AUTOMATIC VOLTAGE REGULATOR
1
7
0027105016
MACHINE SCREW
4
8
0601806118
CURRENT TRANSFORMER, 200:5A ............ 3 ................. S/N 7800001~7800129
9
0027106016
MACHINE SCREW
6
10
0601820845
OVER CURRENT RELAY .............................. 1 ................. S/N 7800001~7800057
10
0601820847
OVER CURRENT RELAY .............................. 1 ................. S/N 7800058~7800129
11
0601820846
OVER CURRENT RELAY .............................. 1 ................. S/N 7800001~7800057
11
0601820848
OVER CURRENT RELAY .............................. 1 ................. S/N 7800058~7800129
12
0027104016
MACHINE SCREW
2
13
0207004000
HEX NUT
2
14
0601826158
CAPACITOR, 0.01uF
1
15
M3213500013
CONTROL BOX COVER
1
16
0016906016
HEX HEAD BOLT
4
17
M3923100004
SELECTOR SWITCH .................................... 1 ................. S/N 7800001~7800129
17A
S2BG411
KNOB-HANDLE, BLACK
18
M3276600004
SPACER
8
19
M3213600003
SWITCH BRACKET ...................................... 1 ................. S/N 7800001~7800129
20
0330000295
EDGING ........................................................ 2 ................. S/N 7800001~7800129
21
M3260500004
SWITCH BOARD
1
22
0021104015
MACHINE SCREW ....................................... 4 ................. S/N 7800001~7800129
22A
0207004000
HEX NUT
4
22B
0040004000
WASHER, LOCK
4
22C
0041204000
WASHER, FLAT
4
20
0330000295
EDGING ........................................................ 2 ................. S/N 7800001~7800129
23
0016906016
HEX HEAD BOLT .......................................... 6 ................. S/N 7800001~7800129
24
M3213600104
SWITCH COVER ........................................... 1 ................. S/N 7800001~7800129
25
0016906016
HEX HEAD BOLT .......................................... 4 ................. S/N 7800001~7800129
26
0016906016
HEX HEAD BOLT ........................................ 10 ................. S/N 7800001~7800129
27
M3223000203
CONTROL PANEL
1
28
0601807641
FREQUENCY METER, 45~65Hz 240V
1
29
0601808988
AC AMMETER, 0~200A/400A
1
30
0601801040
CHANGE-OVER SWITCH, AMMETER
1
31
0601806859
AC VOLTMETER, 0~600V
1
32
0601801041
CHANGE-OVER SWITCH, VOLTMETER
1
33
0601840073
RHEOSTAT (VR) 2W 1K OHM
1
34
0601840121
KNOB
1
35
M1223100004
STOPPER
1
36
0027105016
MACHINE SCREW
2
37
0027105016
MACHINE SCREW
4

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 59

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (CONT. S/N 7800001~7800129)

PAGE 60 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000001~78000129)
CONTROL BOX ASSY. (CONT. S/N 7800001~7800129)
NO
38
39
40
41
42
42
43
43
44
44A
4B
45
45A
45B
46
47
48
49
50
51
52
53

PART NO
M9220100004
0080200007
0601826031
0027104016
0601823240
0601823240
0027104030
0027104040
LY2DUS12VDC
0601823109
0601824400
0601823768
0601823109
0601824400
0027104020
0602202568
0027105016
0602120475
0016906020
M3246701304
V20405778
V20412270

PART NAME
QTY.
REMARKS
SET SCREW
1
SNAP RING
1
RELAY, DC12V
1
MACHINE SCREW
2
RECTIFIER, DE4503 ........................................ 2 ............. S/N 7800001~7800002
RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800003~7800129
MACHINE SCREW ........................................... 1 ............. S/N 7800001~7800002
MACHINE SCREW ........................................... 1 ............. S/N 7800003~7800129
RELAY
1
REPLACES P/N 0601827656
RELAY BASE, PTF08A-E
1
RELAY CLIP, PYCA1
2
RELAY, LY-2 DC12V
1
RELAY BASE, PTF08-E
1
RELAY CLIP, PYCA1
2
MACHINE SCREW
4
SPEED CONTROL UNIT
1
MACHINE SCREW
4
SPEED SENSOR
1
HEX HEAD BOLT
1
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800000~7800129
OIL PRESSURE SENSOR
1
SENSOR TEMPERATURE
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 61

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (S/N 7800130~AND ABOVE)

PAGE 62 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (S/N 7800130~AND ABOVE)
NO
PART NO
PART NAME
QTY.
REMARKS
1
M321300902
CONTROL BOX ................................................. 1 ............. S/N 7800130~7800214
1
M321300912
CONTROL BOX ................................................. 1 ............. S/N 7800215 AND ABOVE
2
0601808822
CIRCUIT BREAKER, 3P 250A
1
3
0021005080
MACHINE SCREW
4
4
0601823863
RELAY UNIT
2
5
0027104016
MACHINE SCREW
4
6
0601820671
AUTOMATIC VOLTAGE REULATOR
1
7
0027105016
MACHINE SCREW
4
8
0601806118
CURRENT TRANSFORMER, 200:5A ................ 3 ............. S/N 7800130~7800214
8
0601801124
CURRENT TRANSFORMER, 200:5A ................ 3 ............. S/N 7800215 AND ABOVE
9
0027106020
MACHINE SCREW ........................................... 6 ............. REPLACES P/N 0027106016
10
0601820847
OVER CURRENT RELAY .................................. 1 ............. S/N 7800130 AND ABOVE
11
0601820848
OVER CURRENT RELAY .................................. 1 ............. S/N 7800130 AND ABOVE
12
0027104016
MACHINE SCREW
2
13
0207004000
HEX NUT
2
14
0601826158
CAPACITOR, 0.01uF
1
15
M3213500213
CONTROL BOX COVER ................................... 1 ............. S/N 7800130 AND ABOVE
16
0016906016
HEX HEAD BOLT
5
17
M3270100404
SELECTOR SWITCH ........................................ 1 ............. S/N 7800130~AND ABOVE
17A
S2BG411
KNOB-HANDLE, BLACK
17B
M3550002304
DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE
17C
M3550002404
DECAL, SELECTOR SWITCH NUMBER .......... 1 ............. S/N 7800195~AND ABOVE
18
M3276600004
SPACER
8
19
M3213600903
SWITCH BRACKET .......................................... 1 ............. S/N 7800130~7800194
19
M3213601504
SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE
20
0330000295
EDGING ............................................................ 2 ............. S/N 7800130~7800194
21
M3260500004
SWITCH BOARD
1
22
0021104015
MACHINE SCREW ........................................... 4 ............. S/N 7800130~7800194
22
0021104040
MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE
22A
0207004000
HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE
22B
0040004000
WASHER, LOCK ............................................... 4 ............. S/N 7800195~AND ABOVE
22C
0041204000
WASHER, PLAIN .............................................. 4
20
0330000295
EDGING ............................................................ 2 ............. S/N 7800001~7800194
23
0016906016
HEX HEAD BOLT .............................................. 8 ............. S/N 7800130~7800194
23
0016906016
HEX HEAD BOLT .............................................. 6 ............. S/N 7800195~AND ABOVE
24
M3213601004
SWITCH COVER ............................................... 1 ............. S/N 7800130~7800194
24
M3213601704
SWITCH COVER ............................................... 1 ............. S/N 7800195~AND ABOVE
24-1 0228800210
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
24-2 0228800120
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
24-3 0317700180
SEAL RUBBER ................................................. 1 ............. S/N 7800195~AND ABOVE
25
0016906016
HEX HEAD BOLT .............................................. 4 ............. S/N 7800001~7800129

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 63

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (CONT. S/N 7800130~AND ABOVE)

PAGE 64 — DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07)

DCA-100SSVU— CONTROL BOX ASSY. (S/N 78000130 AND ABOVE)
CONTROL BOX ASSY. (CONT. S/N 7800130~AND ABOVE)
NO
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
44A
44B
45
45A
45B
46
47
48
49
50
51
52
53-1
53-2
53-3
54
54-1
55
55A
56
57
58
59

PART NO
0016906016
M3223000203
0601807641
0601808988
0601801040
0601806859
0601801041
0601840073
0601840121
M1223100004
0027105016
0027105016
M9220100004
0080200007
0601826031
0027104016
0601823240
0027104040
0601827656
PTF08A
PYCA1
LY2DUS12VDC
PTF08A
PYCA1
0027104020
0602202568
0027105016
0602120475
0016906020
M3260500204
0016906016
0330000180
0330000240
0330000065
M3213601604
0330000225
0027104016
02070004000
M3246701304
M3246701324
V20405778
V20412270

PART NAME
QTY.
REMARKS
HEX HEAD BOLT .............................................15 ............. S/N 7800130~AND ABOVE
CONTROL PANEL
1
FREQUENCY METER, 45~65Hz 240V
1
AC AMMETER, 0~200A/400A
1
CHANGE-OVER SWITCH, AMMETER
1
AC VOLTMETER, 0~600V
1
CHANGE-OVER SWITCH, VOLTMETER
1
RHEOSTAT (VR) 2W 1K OHM
1
KNOB
1
STOPPER
1
MACHINE SCREW
2
MACHINE SCREW
4
SET SCREW
1
SNAP RING
1
RELAY, DC12V
1
MACHINE SCREW
2
RECTIFIER, DE4503 ........................................ 3 ............. S/N 7800130~AND ABOVE
MACHINE SCREW ........................................... 1 ............. S/N 7800130~AND ABOVE
RELAY, LY-2D DC12V
1
RELAY BASE .................................................... 1 .............. REPLACES P/N 0601823109
RELAY CLIP...................................................... 2 .............. REPLACES P/N 0601824400
RELAY, .............................................................. 1 .............. REPLACES P/N 0601823768
RELAY BASE .................................................... 1 .............. REPLACES P/N 0601823109
RELAY CLIP...................................................... 2 .............. REPLACES P/N 0601824400
MACHINE SCREW
4
SPEED CONTROL UNIT
1
MACHINE SCREW
4
SPEED SENSOR
1
HEX HEAD BOLT
1
SET PANEL ....................................................... 1 ............. S/N 7800130~AND ABOVE
HEX HEAD BOLT .............................................. 4 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 1 ............. S/N 7800130~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE
SWITCH BRACKET .......................................... 1 ............. S/N 7800195~AND ABOVE
EDGING ............................................................ 2 ............. S/N 7800195~AND ABOVE
MACHINE SCREW ........................................... 4 ............. S/N 7800195~AND ABOVE
HEX NUT .......................................................... 4 ............. S/N 7800195~AND ABOVE
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800130~7800194
WIRE HARNESS GENERATOR ........................ 1 ............. S/N 7800195~AND ABOVE
OIL PRESSURE SENSOR
1
SENSOR TEMPERATURE
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 65

DCA-100SSVU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.

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

DCA-100SSVU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO
1
1-1
1-2
1-3
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

PART NO
M3923200044
V3840033
V3831236
V20549350
M3303200204
M3303200304
0012112040
0030312000
0042512000
0605000450
0030012000
0040012000
M3310201104
0016908020
M3310200814
0283202350
0222900510
0016906020
0602022563
0802022561
0803306590
0603300285
0605511395
0603306395
0802021070
0269200800
M3310600104
0199800800
0193101200
V978515
V20405794
V978750
V20412278
V20412279
V20405779
V20543720

PART NAME
QTY.
REMARKS
ENGINE & RADIATOR SET .............................. 1 ............. TAD520GE
ELEMENT, AIR CLEANER ................................ 1 ............. REPLACES P/N 0602046622
CARTRIDGE, OIL FILTER ................................ 1 ............. REPLACES P/N 0602041277
CARTRIDGE, FUEL FILTER ............................. 1 ............. REPLACES P/N 0602042560
ENGINE FOOT
1
ENGINE FOOT
1
HEX HEAD BOLT
4
HEX NUT
4
WASHER, LOCK
4
RUBBER SUSPENSION
2
HEX NUT
2
WASHER, LOCK
2
RADIATOR BRACKET
2
HEX HEAD BOLT
4
SEAL BRACKET
1
SEAL RUBBER
1
SEAL RUBBER
2
HEX HEAD BOLT
6
ADAPTER
1
90 DEG. ELBOW
1
CONNECTOR
1
ROCKNUT
1
VALVE
1
HOSE JOINT
1
CAP
1
DRAIN HOSE
1
DRAIN JOINT
1
DRAIN HOSE
1
OVER FLOW HOSE
1
V-BELT ALTERNATOR
1
ALTERNATOR
1
V-BELT, FUEL PUMP
1
HOSE RADIATOR, UPPER
1
HOSE RADIATOR
1
MONITOR, OIL PRESSURE
1
TEMPERATURE SENSOR UNIT
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 67

DCA-100SSVU— OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.

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

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

THE SERIAL NUMBER MAY BE REQUIRED.

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

DCA-100SSVU— OUTPUT TERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
1
2
3
4
5
6
7
8
9
10
11
11A
11B
12
12A
13
14
15
16
17
18
19
20
20-1
21
22
23
24
24A
25
26
27
28
29
30
31
32
33

PART NO
M3230700003
M9220100304
M9220100404
0039316000
0040016000
0041416000
0016908035
M3238100103
M3236100104
0606010040
0027103010
0030003000
0041203000
0027103010
0030003000
0016906020
0016906016
M3236400004
M3236300004
0016906020
0601808803
0601808804
M1260700304
0222100150
0016906020
0601812598
0601812538
0027104016
0207004000
M3236100213
0010112045
0041212000
M9310200004
0030012000
0603306775
0027104016
0601815194
0027104016

PART NAME
TERMINAL PANEL
OUTPUT TERMINAL BOLT
TIE BOLT
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX HEAD BOLT
TERMINAL COVER
OUTPUT WINDOW
HINGE
MACHINE SCREW
HEX NUT
WASHER, FLAT
MACHINE SCREW
HEX NUT
HEX HEAD BOLT
HEX HEAD BOLT
CABLE OUTLET COVER
SUPPORTER, CABLE OUTLET COVER
HEX HEAD BOLT
CIRCUIT BREAKER, 120V,1P 20A
CIRCUIT BREAKER, 250V, 2P 50A
BREAKER FITTING COVER
CUSHION RUBBER
HEX HEAD BOLT
RECEPTACLE, 125V 20A X 2
RECEPTACLE, CS6369 250V 50A
MACHINE SCREW
HEX NUT
TERMINAL COVER
HEX HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX NUT
BIND PLUG
MACHINE SCREW
TERMINAL
MACHINE SCREW

QTY.
1
5
5
10
15
20
5
1
1
2
4
4
4
4
4
2
4
1
1
6
2
3
1
1
2
2
2
10
10
1
2
2
2
2
2
4
1
2

REMARKS

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 69

DCA-100SSVU — ACTUATOR ASSY.
ACTUATOR ASSY.

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

DCA-100SSVU — ACTUATOR ASSY.
ACTUATOR ASSY.
NO
1
2
3
4
4A
4B
4C
5
5A
6
7
8
9
10
11
12
13
14

PART NO
0602150070
M3354200004
0021108020
0014208035
0030008000
0040008000
0041208000
0014208035
0041208000
M3354300404
0602180290
0038202000
M3351800004
0041208000
0010106040
0030006000
0041206000
0017106025

PART NAME
ACTUATOR
ACTUATOR BRACKET
FLAT HEAD SCREW
HEX SOCKET HEAD CAP SCREW
HEX NUT
WASHER, LOCK
WASHER, FLAT
HEX SOCKET HEAD CAP SCREW
WASHER, FLAT
THROTTLE THREAD
ROD END
HEX NUT
COLLAR
PLAIN WASHER
HEX HEAD BOLT
HEX NUT
WASHER, FLAT
HEX HEAD BOLT

QTY.
1
1
2
1
1
1
2
1
1
1
2
2
1
3
1
2
3
1

REMARKS

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 71

DCA-100SSVU— BATTERY ASSY.
BATTERY ASSY.

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

DCA-100SSVU— BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
8
9
9A
10
10A

PART NO
0602220196
M9310500404
M9103000504
0602220921
0040006000
M3346900804
M3346900604
0017112025
0040512000
0017110020
0040510000

PART NAME
QTY.
REMARKS
BATTERY
1
BATTERY SHEET
1
BATTERY BAND
1
BATTERY BOLT SET
2
SPRING WASHER
2
BATTERY CABLE
1
BATTERY CABLE
1
CABLE .............................................................. 1 ............. MAKE LOCALLY
HEX HEAD BOLT
1
TOOTHED WASHER
1
HEX HEAD BOLT
1
TOOTHED WASHER
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 73

DCA-100SSVU— MUFFLER ASSY.
MUFFLER ASSY.

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

DCA-100SSVU— MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2
3
3
4
5
6
7
8
9
10
11

PART NO
0602300167
0016910025
M3333000713
M333000733
0602320198
M3333200004
0017110040
0017110040
M3330400304
M3330400403
0016908020
0602326061

PART NAME
QTY.
REMARKS
MUFFLER
1
HEX HEAD BOLT
4
EXHAUST PIPE ................................................ 1 ............. S/N 7800001~7800012
EXHAUST PIPE ................................................ 1 ............. S/N 7800013 AND ABOVE
GASKET
1
GASKET
1
HEX HEAD BOLT
4
HEX HEAD BOLT
4
COVER
1
BRACKET
1
HEX HEAD BOLT
4
U-BOLT SET
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 75

DCA-100SSVU— FUEL TANK ASSY.
FUEL TANK ASSY.

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

DCA-100SSVU— FUEL TANK ASSY.
FUEL TANK ASSY.
NO
1
1-1
2
3
4
5
6
7
8
9
10
11
12
13
13A
14
15
16
18
18
19
20
21
21
22
23
24
24A
25

PART NO
M3363001002
0605505070
M3363200204
M9310500104
0016908020
0207308000
0222100660
M9200000003
M9200200004
0150000018
0016906020
M1363400104
0605515198
0602042266
0602042766
0017110040
0602022567
0602022980
0191401250
0191401050
0191400770
0191302900
0605515198
0605515198
0605515109
0602023200
0017106045
0207006000
0191400135

PART NAME
QTY.
REMARKS
FUEL TANK
1
CAP, FUEL TANK
1
TANK BAND
2
SUPPORTER SHEET
4
HEX HEAD BOLT
2
HEX NUT
2
RUBBER SHEET
2
DRAIN JOINT
1
DRAIN BOLT
1
O RING
1
HEX HEAD BOLT
2
DRAIN HOSE
1
HOSE BAND
2
WATER SEPARATOR
1
ELEMENT
1
HEX HEAD BOLT
2
90 DEG. ELBOW
2
SWIVEL
2
SUCTION HOSE ............................................... 1 ............. S/N 7800081 AND BELOW
SUCTION HOSE ............................................... 1 ............. S/N 7800082 AND ABOVE
SUCTION HOSE
1
RETURN HOSE
1
HOSE BAND ..................................................... 4 ............. S/N 7800081 AND BELOW
HOSE BAND ..................................................... 6 ............. S/N 7800082 AND ABOVE
HOSE BAND
2
FUEL HAND PUMP ............................................ 1 ............. S/N 7800082 AND ABOVE
HEX HEAD BOLT ............................................... 2 ............. S/N 7800082 AND ABOVE
HEX NUT ........................................................... 2 ............. S/N 7800082 AND ABOVE
SUCTION HOSE ................................................ 1 ............. S/N 7800082 AND ABOVE

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 77

DCA-100SSVU— ENCLOSURE ASSY.
ENCLOSURE ASSY.

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

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

THE SERIAL NUMBER MAY BE REQUIRED.

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

DCA-100SSVU— ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO
1
2
3
4
4A
5
6
6A
7
7
8
8A
9
9A
9B
9C
10
10
10A
11
11A
12
13
13A
14
15
15
16
17
18
18A
19
20
20A
21
21A
22
22
23
24
24
24A
25
25A

PART NO
M3413001612
M1413400004
0016908020
M3423001012
M3493105713
0016910025
M3423200104
M3493100304
0016908020
0019208020
M3433000712
M3493200004
0010114040
0030014000
0040014000
0041214000
M344300212
M3443001002
M3493300204
0016910025
0040510000
M3443300203
M3443300903
M3493302603
0207006000
0016908020
0019208020
M3443200113
M3443600104
0207306000
0041206000
M9113000002
0021806016
0030006000
M9110100204
M9116100004
0016908020
0019208020
M9310000004
M3463100603
M3463100613
M3493502703
M3463200403
M3493502803

PART NAME
QTY.
REMARKS
BASE
1
UNDER COVER
1
HEX HEAD BOLT
2
FRONT FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT
6
COVER, FRONT FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT .......................................... 14 ............... S/N 7800001~7800099
HEX HEAD BOLT .......................................... 14 ............... S/N 7800100 AND ABOVE
CENTER FRAME
1
ACOUSTIC SHEET
1
HEX HEAD BOLT
12
HEX NUT
12
WASHER, LOCK
24
WASHER, FLAT
24
REAR FRAME................................................. 1 ............... S/N 7800001~7800129
REAR FRAME................................................. 1 ............... S/N 7800130 AND ABOVE
ACOUSTIC SHEET
1
HEX HEAD BOLT
4
TOOTHED WASHER
1
REAR COVER
1
DUCT, REAR COVER
2
ACOUSTIC SHEET
1
HEX NUT
12
HEX HEAD BOLT .......................................... 10 ............... S/N 7800001~7800099
HEX HEAD BOLT .......................................... 10 ............... S/N 7800100 AND ABOVE
REAR DOOR
1
WINDOW PLATE
1
HEX NUT
10
WASHER, FLAT
10
DOOR HANDLE ASSY.
1
MACHINE SCREW
4
HEX NUT
4
HINGE
2
WASHER
2
HEX HEAD BOLT ............................................ 3 ............... S/N 7800001~7800099
HEX HEAD BOLT ............................................ 3 ............... S/N 7800100 AND ABOVE
BLIND PLUG
2
ROOF PANEL .................................................. 1 ............... S/N 7800001~7800214
ROOF PANEL .................................................. 1 ............... S/N 7800215 AND ABOVE
ACOUSTIC SHEET
1
ROOF PANEL
1
ACOUSTIC SHEET
1

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 79

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)

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

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

THE SERIAL NUMBER MAY BE REQUIRED.

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

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
NO
26
27
27
28
29
30
30A
31
31
32
33
33A
34
34A
35
35A
36
36A
37
37A
38
39
39A
40
40A
41
42
43
44
44A
45
46
46
47
47A
48
48A
49
49
50
51
52
53
53A
54
55

PART NO
M3463500404
0016908020
0019208020
M9310000103
M1483600204
M3453200512
M3493411904
0016908055
0019208055
M3453001813
M3453001813
M3493411414
M3453002403
M3493411414
M3453002003
M3493411604
M3453002113
M3493411714
M3453302103
M3493411314
M3453302003
M3453301903
M3493411514
M3453302203
M3493411814
0207006000
0016906016
M9113000002
0021806016
0030006000
M3453700314
0016906016
0019206016
M9110100204
M9116100004
M9110100304
M9116100004
0016908020
0019208020
0601850097
0027208025
M9310000004
0016908020
0040508000
M1465400104
0019208020

PART NAME
QTY.
REMARKS
OVER COVER, FRONT FRAME
1
HEX HEAD BOLT .......................................... 37 ............... S/N 7800001~7800099
HEX HEAD BOLT .......................................... 37 ............... S/N 7800100 AND ABOVE
BONNET CAP ................................................. 1 ............... S/N 7800001~7800214
CHAIN ASSY .................................................. 2 ............... S/N 7800001~7800214
SPLASHER PANEL
1
ACOUSTIC SHEET
1
HEX HEAD BOLT ............................................ 4 ............... S/N 7800001~7800099
HEX HEAD BOLT ............................................ 4 ............... S/N 7800100 AND ABOVE
HEX HEAD BOLT
2
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
SIDE DOOR
1
ACOUSTIC SHEET
1
DUCT
1
ACOUSTIC SHEET
1
DUCT
1
DUCT
1
ACOUSTIC SHEET
1
DUCT
1
ACOUSTIC SHEET
1
HEX NUT
34
HEX HEAD BOLT
5
DOOR HANDLE ASSY.
4
MACHINE SCREW
16
HEX NUT
16
GUTTER
1
HEX HEAD BOLT ............................................ 2 ............... S/N 7800001~7800099
HEX HEAD BOLT ............................................ 2 ............... S/N 7800100 AND ABOVE
HINGE
4
WASHER
4
HINGE
4
WASHER
4
HEX HEAD BOLT ............................................ 9 ............... S/N 7800001~7800099
HEX HEAD BOLT ............................................ 9 ............... S/N 7800100 AND ABOVE
STOPPER
8
MACHINE SCREW
8
BLIND PLUG
8
HEX HEAD BOLT
1
TOOTHED WASHER
1
COVER ............................................................ 1 ............... S/N 7800215 AND ABOVE
HEX HEAD BOLT ............................................ 2 ............... S/N 7800215 AND ABOVE

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 81

DCA-100SSVU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.

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

DCA-100SSVU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO
PART NO
1
0228900785
2
0229200725
3
0228901020
4
0228900990
5
0228901060
6
0228900470
7
0229201100
8
0229201040
9
0228800630
10
0228800970
11
0228800590
12
0228100665
13
0228100370
14
0228100300
15
0228100365
16
0228100280
17
0228100070

PART NAME
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER
SEAL RUBBER

QTY.
3
1
2
4
4
2
4
1
1
2
1
1
1
1
1
1
1

REMARKS

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 83

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.

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

NAMEPLATE AND DECALS ASSY.

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
1-1
M3552000403
DECAL; OPERATING PROCEDURES ................... 1 .................... M35200040
1-2
M9520100304
DECAL; SAFETY INSTRUCTIONS ........................ 1 .................... M92010030
1-3
M9520100603
DECAL; CAUTION .................................................. 2 .................... M92010060

2-7

M3550001403
M9520000104
M9520000204
M9520100004
M9520100204
M9520200104
M9520200404
M3550001503

CONTROL PANEL, BOX & OPERATING PANEL GROUP
DECAL; CONTROL PANEL .................................... 1 .................... M35000140
PLATE; AMMETER CHANGE-OVER SWITCH ...... 1 .................... M92000010
PLATE; VOLTMETER CHANGE-OVER SWITCH ... 1 .................... M92000020
DECAL; WARNING ELECTRIC SHOCK HAZARD . 1 .................... M92010000
DECAL; CAUTION .................................................. 1 .................... M92010020A
DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020010
DECAL; OVER CURRENT RELAY ......................... 1 .................... M92020040
DECAL; OPERATING PANEL ................................. 1 .................... M35000150

3-1
3-2
3-3
3-4
3-5
3-6

M9500000004
M9500100004
M9503000004
M9503000103
M9503100004
M9510100004

ENGINE & RADIATOR GROUP
DECAL; OIL DRAIN PLUG ..................................... 1 .................... M90000000
DECAL; WATER ...................................................... 1 .................... M90010000
DECAL; WARNING MOVING PARTS ..................... 2 .................... M90300000
DECAL; WATER * OIL CHECK ............................... 1 .................... M90300010
DECAL; WARNING HOT COOLANT ....................... 1 .................... M90310000
DECAL; CAUTION HOT PARTS ............................. 1 .................... M91010000

4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9

M1550000204
M1550000703
M3550000304
M9520000004
M9520000504
M9520100004
M9520100404
M9520100503
M9520200003

OUTPUT TERMINAL GROUP
DECAL; NOTE ........................................................ 1 .................... M15000020
DECAL; RECEPTACLE & CIRCUIT BREAKER ..... 1 .................... M15000070
DECAL; NOTE ........................................................ 1 .................... M35000030
DECAL; GROUND .................................................. 1 .................... M92000000
DECAL; START CONTACT ..................................... 1 .................... M92000050
DECAL; WARNING ELECT. SHOCK HAZARD ....... 1 .................... M92010000
DECAL; DANGER HIGH VOLTAGE ........................ 1 .................... M92010040
DECAL; WARNING ................................................. 1 .................... M92010050
DECAL; OUTPUT TERMINAL ................................ 1 .................... M92020000

5-1
5-2
5-3

M9500300004
M9500300104
M9510100403

BATTERY GROUP
DECAL; - ................................................................ 1 .................... M90030000
DECAL; + ............................................................... 1 .................... M90030010
DECAL; CAUTION .................................................. 1 .................... M91010040

2-1
2-2
2-3
2-4
2-5
2-6

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 85

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.

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

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
MUFFLER GROUP
6-1
M9503200004
DECAL; WARNING ENGINE EXHAUST ................. 1 .................... M90320000
7-1
7-2
8-1
8-2
9-2A
8-3
8-4
8-5
8-6
8-7
8-8
8-9

M9500500004
M9500500104

FUEL TANK GROUP
DECAL; DIESEL FUEL .......................................... 1 .................... M90050000
DECAL; FUEL DRAIN PLUG .................................. 1 .................... M90050010

M9510200002
0600500090
0021106015
M3560100003
M3560100103
M3560101904
M3560100404
M3560101704
M3560101804
M3560100604

ENCLOSURE GROUP
DECAL; MQ ............................................................ 1 .................... M91020000
EMBLEM
1
MACHINE SCREW
2
STRIPE
1
STRIPE
2
STRIPE
2
STRIPE
2
STRIPE
1
STRIPE
1
STRIPE
2

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 87

Effective: October 1, 2002
PAYMENT TERMS

TERMS AND CONDITIONS OF SALE — PARTS
5.

Parts must be in new and resalable condition, in the original Multiquip package (if
any), and with Multiquip part numbers
clearly marked.

The following items are not returnable:

Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.

a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)

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

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

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

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

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

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.

A $35.00 surcharge will be added to the invoice
for special handling including bus shipments,
insured parcel post or in cases where Multiquip
must personally deliver the parts to the carrier.

c. Any line item with an extended dealer
net price of less than $5.00.

f. Paint, chemicals, and lubricants.

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.

g. Decals and paper products.

LIMITATION OFWARRANTIES

h. Items purchased in kits.

No warranties, express or implied, are made in
connection with the sale of parts or trade
accessories nor as to any engine not manufactured by Multiquip. Such warranties made in
connection with the sale of new, complete units
are made exclusively by a statement of warranty packaged with such units, and Multiquip
neither assumes not authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products. Apart from such written statement of
warranty, there are no warranties, express,
implied or statutory, which extend beyond the
description of the products on the face hereof.

d. Special order items.

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

for price declines and added charges for price
increases will not be made for stock on hand at
the time of any price change.

e. Electrical components.

The sender will be notified of any
material received that is not acceptable.

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

Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.

10. In cases where an item is accepted, for
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.

LIMITATIONS OF SELLER’S LIABILITY

11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific date and all orders received on or after that
date will be billed at the revised price. Rebates

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

NOTE PAGE

1
DCA-100SSVU— OPERATION AND PARTS MANUAL — REV. #0 (11/05/07) — PAGE 89

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MQ POWER CORPORATE OFFICE
18910 Wilmington Ave.
800-421-1244
FAX: 310-632-2656
Carson, CA 90746
Email: mqpower@multiquip.com
Internet: www.mqpower.com
PARTS DEPARTMENT
800-427-1244
FAX: 800-672-7877
310-537-3700
FAX: 310-637-3284
SERVICE DEPARTMENT
800-835-2551
FAX: 310-638-8046
310-537-3700
TECHNICAL ASSISTANCE
800-835-2551
FAX: 310-638-8046
WARRANTY DEPARTMENT
800-835-2551, EXT. 279
FAX: 310-638-8046
310-537-3700, EXT. 279

Manufactured for Multiquip Inc.
by
DENYO CO., LTD, JAPAN

Your Local Dealer is:
MQ POWER
A Division of Multiquip Inc.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: 310-632-2656
E-mail: mqpower@multiquip.com
Internet: www.mqpower.com

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EXIF Metadata provided by EXIF.tools

Multiquip Mq Power Whisperwatt 60 Hz Generator Dca 100Ssvu Users Manual Rev 0.pmd

MQ Power Whisperwatt 60 Hz Generator DCA-100SSVU Generators_portable_whisperwatt_DCA100SSVU_rev_0_manual_DataId_19082_Version_1

DCA-100SSVU to the manual d6e91941-c562-4f96-bcf0-bae06917250f

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