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

Revision #0 (11/05/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

WHISPERWATTTM SERIES

MODEL DCA-100SSVU

60 Hz GENERATOR

PARTS LIST NO. M3870300704F

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

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

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

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

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

TABLE OF CONTENTS

Specification and part

number are subject to

change without notice.

NOTE

MQ POWER DCA-100SSVUMQ POWER DCA-100SSVU

MQ POWER DCA-100SSVU

WHISPERWHISPER

WHISPERWW

WAA

ATTTT

TTTT

TTTMTM

TMTM

GENERATORGENERATOR

GENERATOR

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

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

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

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

When ordering parts,

please supply the following information:

❒❒

❒Dealer account number

❒❒

❒Dealer name and address

❒❒

❒Shipping address (if different than billing address)

❒❒

❒Return fax number

❒❒

❒Applicable model number

❒❒

❒Quantity, part number and description of each part

❒❒

❒Specify preferred method of shipment:

✓FedEx or UPS Ground

✓FedEx or UPS Second Day or Third Day

✓FedEx or UPS Next Day

✓Federal Express Priority One

✓DHL

✓Tr uck

Note: Unless otherwise indicated by customer, all

orders are treated as “Standard Orders”, and will

ship within 24 hours. We will make every effort to

ship “Air Shipments” the same day that the order is

received, if prior to 2PM west coast time. “Stock

Orders” must be so noted on fax or web forms.

Extra Discounts!

All parts orders which include complete part numbers and

are received by our automated web parts order system, or

by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances

when you order 10 or more

line items via Web or Fax!**

FedEx Ground Service

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.

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

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

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7 (800/672-7877)

PARTS ORDERING PROCEDURES

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

DCA-100SSVU — SPECIFICATIONS

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

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

Figure 1. Dimensions

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

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.

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.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! 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

NOTE

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you

about potential hazards that could injure you or others. The

Safety Messages specifically address the level of exposure

to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

You WILL be KILLED or SERIOUSLY injured if you

do not follow directions.

You COULD be KILLED or SERIOUSLY injured if

you do not follow directions.

You CAN be injured if you do not follow directions

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.

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.

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.

WARNING

DANGER

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, there

exists the possibility of

electrocution,

electrical shock or burn,

which can cause

severe bodily harm

or even

DEATH!

DANGER - ELECTROCUTION HAZARDS

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

DCA-100SSVU — SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the engine ON/OFF

switch (MPEC) in the OFF/RESET

position when the generator is not in use.

ALWAYS wear approved

respiratory

protection.

ALWAYS wear approved

eye

and

hearing

protection.

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.

NOTE

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.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,

or guards removed. Keep

fingers

hands

hair

and clothing away from all moving

parts to prevent injury.

WARNING - ROTATING PARTS

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

DCA-100SSVU — RULES FOR SAFE OPERATION

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.

The operator MUST BE familiar with proper safety

precautions and operations techniques before using

generator.

■

This equipment should not be operated by persons under

18 years of age.

■

NEVER operate this equipment without proper protective

clothing, shatterproof glasses, steel-toed boots and other

protective devices required by the job.

■

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.

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.

DANGER - READ THIS 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 engine of this generator requires an adequate free

flow of cooling air.

NEVER

operate the generator in any

enclosed or narrow area where free flow of the air is

restricted. If the air flow is

restricted it will cause serious

damage to the generator or

engine and may cause injury

to people. The generator

engine gives off DEADLY

carbon monoxide gas.

■

DO NOT place hands or fingers inside generator engine

compartment when engine is running.

■

NEVER run engine without air filter. Severe engine damage

may occur.

■

DO NOT leave the generator running in the

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.

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

DCA-100SSVU — RULES FOR SAFE OPERATION

POWER

CORD

(POWER ON)

WET

HANDS

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

may cause damage to the generator

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.

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

DANGER - ELECTROCUTION HAZARDS

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

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.

■

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 wate

■

NEVER

stand in water

while AC power from the generator

is being transfer to a load.

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

DCA-100SSVU — RULES FOR SAFE OPERATION

Battery Safety

Use the following guidelines when handling the battery:

■

The battery contains acids that can

cause injury to the eyes and skin. To

avoid eye irritation,

always

wear safety

glasses.

■

Use well insulated gloves when picking up the battery.

Maintenance 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.

■

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.

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.

■

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.

WARNING - BURN HAZARDS

■■

■

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.

The risk of an explosion exists when performing service

on the battery. To avoid

severe injury

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.

DANGER - EXPLOSION HAZARDS

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

Emergencies

■

ALWAYS know the location of the

nearest

fire extinguisher

■

ALWAYS know the location of the

nearest and

first aid kit

■

ALWAYS know the location of the

nearest phone or

keep a phone on

the job site,

in case of emergencies.

■

ALWAYS have easy access to the phone

numbers of the nearest

Ambulance

Doctor

and

Fire Department

. This information will

be invaluable in the case of an emergency.

DCA-100SSVU — RULES FOR SAFE OPERATION

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.

CAUTION - FOLLOW TOWING REGULATIONS

■

The maximum speed for highway towing is 55 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 15 MPH or less depending on type of

terrain.

■

Place

chock blocks

underneath wheel to prevent rolling,

while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to

a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding,

or jack-knifing. Smooth, gradual starts and stops will

improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times

when towing.

■

Raise and lock trailer wheel stand in up position when

transporting.

■

The maximum speed for highway towing is 55 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 15 MPH or less depending on type of

terrain.

■

Place

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Towing & Transporting Safety

To reduce the possibility of an accident while transporting

the generator on public roads, always make sure the trailer

that supports the generator and the towing vehicle are in

good operating condition and both units are mechanically

sound.

The following list of safety precautions should be followed

when towing your generator:

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. Follow the listed

Towing & Transporting Safety

guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer "gross vehicle

weight rating.”

■

ALWAYS inspect the hitch and coupling for wear. NEVER

tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and

trailer.

Trailer tires should be inflated to 50 psi cold.

Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle

properly.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

DOT Requirements include the following:

Connect and test electric brake operation.

Secure portable power cables in cable tray with tie

wraps.

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

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.

DCA-100SSVU — GENERATOR DECALS

Figure 2. Generator Decals

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

DCA-100SSVU — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

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

Figure 4. Typical Generator Grounding Application

DCA-100SSVU — INSTALLATION

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

Outdoor Installation

Install the generator in a area that is free of debris,

bystanders, and overhead obstructions. Make sure the

generator is on secure level ground so that it cannot slide or

shift around. Also install the generator in a manner so that

the exhaust will not be discharged in the direction of nearby

homes.

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to

engine and alternator parts.

Generator Grounding

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground.

Article 250 (Grounding) of the National Electrical Code (NEC)

provides guide lines for proper grounding and specifies that

the cable ground shall be connected to the grounding system

of the building as close to the point of cable entry as

practical.

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

grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

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

2. When grounding the generator (Figure 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.

When connecting the generator

to any buildings electrical

system ALWAYS consult with

a licensed electrician.

DCA-100SSVU — INSTALLATION

NOTE

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

must be vented to the outside. The engine should be installed

at least two feet from any outside wall. Using an exhaust

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat excessively

and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such

as concrete) and set firmly on the foundation to isolate

vibration of the generator when it is running. The generator

must set at least 6 inches above the floor or grade level (in

accordance to NFPA 110, Chapter 5-4.1). DO NOT remove

the metal skids on the bottom of the generator. They are to

resist damage to the bottom of the generator and to maintain

alignment.

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.

CAUTION - EXHAUST HAZARD

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

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 en-

gine. 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.

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

DCA-100SSVU — MAJOR COMPONENTS

Figure 5. Major Components

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

NOTE PAGE

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

DCA-100SSVU — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-100SSVU

Generator Control Panel

(Figure 6).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the load

is drawing from the generator per leg selected by the

ammeter phase-selector switch.

3. AC Voltmeter – Indicates the output voltage present at

the

U,V, and W Output Terminal Lugs

4. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

5. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the

load connected to any phase of the output terminals, or

to be switched off. This switch does not effect the

generator output in any fashion, it is for current reading

only.

6. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage

between any two phases of the output terminals or to

be switched off.

7. Main Circuit Breaker – This three-pole, 250A main

breaker is provided to protect the the

U,V, and W Output

Terminal Lugs

from overload.

Located behind the generator control panel is the

Generator

Control Box

. This box contains some of the necessary

electronic components required to make the generator

function.

The Control Box is equipped with the following major

components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

■

Three Phase Circuit Breaker

Figure 6. Generator Control Panel

Remember the

overcurrent

relay

monitors the current

flowing from the

U,V, and W

Output Terminal Lugs

to the

load.

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

automatically trip the 250 amp main breaker.

To restore power to the

Output Terminal Panel

, press the

reset

button on the overcurrent relay and place the

main

circuit breaker in the

closed

position (ON).

NOTE

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

Figure 7. Engine Operating Panel

DCA-100SSVU — ENGINE OPERATING PANEL

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

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).

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.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 239

F. The engine

temperature is detected using variable resistive values

from the temperature sending unit. This is considered

major

fault.

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.

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.

9. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical row of status LED's (inset),

that when lit, indicate that an engine malfunction (fault)

has been detected. When a fault has been detected the

engine controller will evaluate the fault and all major

faults will shutdown the generator. During

cranking

cycle

, The MPEC will attempt to crank the engine for

10 seconds before disengaging.

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

Output Terminal Familiarization

The “

Output Terminal Panel

” (Figure 8) is provided with the

following:

■■

■

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

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

■

Two (2) 120V GFCI receptacles @ 20 amp

■■

■

Two (2) GFCI Circuit Breakers @ 20 amps

■■

■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located

on the right-hand side (left from control panel) of the generator.

Lift up on the cover to gain access to receptacles and terminal

lugs.

NOTE Terminal legs “O” and “Ground”

are considered

bonded grounds

Figure 8. Output Terminal Panel

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

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

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.

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

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 counter-

clockwise will

decrease

the voltage.

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

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

single-

phase 240/120 position.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (Output Terminal Lugs)

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.

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

Figure 13. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the

Ouput

Terminal Lugs

or the convenience receptacles (Figure 13).

Make sure to read the operation manual before attempting

to connect a load to the generator.

To protect the output terminals from overload, a

3-pole, 250A

main

circuit breaker is provided. Make sure to

switch ALL circuit breakers to the OFF position prior to

starting the engine.

DCA-100SSVU — OUTPUT TERMINAL PANEL FAMILIARIZATION

Over Current Relay

over current relay

(Figure 14) is connected to the main

circuit breaker. In the event of an overload, both the circuit

breaker and the over current relay may trip. If the circuit

breaker can not be reset, the

reset button

on the over cur-

rent relay must be pressed. The over current relay is lo-

cated in the control box.

Figure 14. Over Current Relay

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

DCA-100SSVU — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage,

frequency

and voltage requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as

the wattage is influenced by the efficiency, power factor and

starting system of the equipment.

Motors and motor-driven

equipment draw much greater

current for starting than during

operation.

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

If wattage is not given on the

equipment's name plate,

approximate wattage may be

determined by multiplying

nameplate voltage by the

nameplate amperage.

The power factor of this generator is 0.8. See Table 5 below

when connecting loads.

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.

■■

■

When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up to

the generating set’s rated output (kW) can be used.

■■

■

When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW)

multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

NOTE

WATTS = VOLTAGE x AMPERAGE

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation:

NOTE

An inadequate size connecting cable which cannot carry the

required load can cause a voltage drop which can burn out

the appliance or tool and overheat the cable. See Table 6.

NOTE

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.

DANGER - ELECTRICAL SYSTEM HAZARDS

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

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly re-

lated to the voltage being supplied at either the output termi-

nals 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 recep-

tacles.

Voltage Selector Switch

The

voltage selector

switch (Figure 16) is located above

the output terminal panel’s

Hard Wire Hook-up Panel

. It

has been provided for ease of voltage selection.

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.

Figure 16. Voltage Selector Switch

DCA-100SSVU — GENERATOR OUTPUTS

Generator Amperage

Table 8 describes the generator’s current output capability

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

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.

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.

CAUTION - CHANGING VOLTAGES

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

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 volt-

age selector switch.)

Figure 17. Voltage

Selector Switch 240/

139V Three Phase

Position

Figure 18. AC Voltmeter

Change-Over Switch

Figure 19. AC Voltmeter Gauge

For 3Ø 208V/1Ø,120V, place

the Voltage Selector Switch

in the 3 Phase 340/139

position.

Figure 21. AC Ammeter

(Amp reading on U lug)

Figure 20. AC Ammeter

Change-Over Switch

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

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

U and read the AC Ammeter Gauge.

The

ammeter

gauge will only

show a reading when the

Output Terminal Lugs

are

connected to a load and in use.

NOTE

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

Figure 22. Voltage Selector Switch 240/139V

Three-Phase Position

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the

Output

Terminal Lugs

.. The voltages at the terminals are depen-

dent on the position of the

Voltage Selector Switch

and the

adjustment of the

Voltage Regulator Control Knob

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

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

position as shown in (Figure 22).

Figure 23. Output Terminal Lugs

240/139V Three Phase Connections

2. Connect the load wires to the

Output Terminal Lugs

shown in (Figure 23).

3. Turn the voltage regulator knob (Figure 24) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

3Ø 208V/1Ø120V Output Terminal Lug Voltages

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

position as shown in Figure 25.

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

Use this position for

3Ø-208 or 1Ø120V.

2. Connect the load wires to the

Output Terminal Lugs

shown in Figure 26.

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 26. Output Terminal Lugs

3Ø-208V/120V Connections

Figure 25. Voltage Selector

Switch 3Ø-208V/1Ø-120V

Three-Phase Position

3. Turn the voltage regulator knob (Figure 25) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

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

Figure 28. Output Terminal Lugs

480/277V Three Phase Connections

2. Connect the load wires to the

Output Terminal Lugs

shown in Figure 28.

Figure 30. Output Terminal Lugs

1Ø-240V/120V Connections

DCA-100SSVU — OUTPUT TERMINAL PANEL CONNECTIONS

UVW

480V

BLACK RED BLUE

480V

277V

480V

277V

WHITE GREEN

277V

GROUND CONNECTION

BE USED

AT ALL TIMES

MUST

UVW

240V 120V

BLACK RED BLUE

120V

WHITE GREEN

NOT USED

GROUND CONNECTION

BE USED

AT ALL TIMES

MUST

Figure 27. Voltage Selector Switch 480/277V

Three-Phase Position

3Ø 480/277 Output Terminal Lug Voltages

1. Place the voltage selector switch in the 3Ø 480/277

position as shown in Figure 27.

3. Turn the voltage regulator knob (Figure 24) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

1Ø 240V/120V Output Terminal Lug Voltages

1. Place the voltage selector switch in the 1Ø 240/120

position as shown in Figure 29.

2. Connect the load wires to the

Output Terminal Lugs

shown in (Figure 30).

Figure 29. Voltage Selector Switch 240/120V

Single-Phase Position

3. Turn the voltage regulator knob (Figure 24) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

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

DCA-100SSVU — SETUP

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

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.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler

hole, but DO NOT overfill. Make sure the generator is level.

and verify that the oil level is maintained between the two

notches (Figure 30) on the dipstick. See Table 9 for proper

selection of engine oil.

Figure 31. Internal Fuel Tank System

Refilling the Fuel System

Fuel Check

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.

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

Fuel spillage on a

hot

engine can cause a

fire

explosion

If fuel spillage occurs, wipe up the spilled fuel completely

to prevent fire hazards. NEVER smoke around or near the

generator.

DANGER - EXPLOSION/FIRE HAZARDS

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

DCA-100SSVU — SETUP

Refueling Procedure:

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).

Figure 32. Only Fill on Level Ground

ONLY! use

#2 diesel fuel

when

refueling.

NOTE

3. NEVER overfill fuel tank – It is important to read the

fuel gauge when filling trailer fuel tank. DO NOT wait for

fuel to rise in filler neck (Figure 34).

Figure 34. Full Fuel Tank

Figure 35. Fuel Expansion

3. Open cabinet doors on the “right side” of the generator

(from generator control panel position). Remove fuel cap

and fill tank (Figure 33).

Figure 33. Fueling the Generator

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.

CAUTION - REFUELING THE GENERATOR

Diesel fuel and its vapors are dangerous

to your health and the surrounding

environment. Avoid skin contact and/or

inhaling fumes.

WARNING - RESPIRATORY HAZARDS

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

expansion. Fuel expands when heated (Figure 35).

CAUTION - REFUELING THE GENERATOR

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

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.

Day-to-day addition of coolant is done from the recovery

tank. When adding coolant to the radiator, DO NOT remove

the radiator cap until the unit has completely cooled. See

Table 12 for engine, radiator, and recovery tank coolant

capacities. Make sure the coolant level in the recovery tank

is always between the "H" and the "L" markings.

Operation Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 13) has been added.

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

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the VOLVO Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect the fan belt for

damage and wear and adjust it in accordance with the VOLVO

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15

mm (Figure 36) when depressed with the thumb as shown

below.

Figure 36. Fan Belt Tension

DCA-100SSVU — SETUP

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

less than 50%.

NOTE

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.

WARNING - BURN HAZARDS

NEVER place hands near

the belts or fan while the

generator set is running.

CAUTION - ROTATING PARTS

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

DCA-100SSVU — SETUP

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the

MPEC Control Switch

is in either

the MANUAL position. ALWAYS make sure that the

MPEC

Control Switch

is in the OFF/RESET position when

connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will ensure

a good connection and will help prevent corrosion around

the battery terminals.

Figure 37. Battery Connections

ALWAYS

disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

Inadequate battery connections may cause poor starting

of the generator, and create other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. When

an inverted circuit connection takes place, the circuit will be

in short circuit instantaneously resulting the alternator failure.

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

into the alternator can cause corrision and damage the

alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for

wear and tightness. Tighten all hose clamps and check hoses

for leaks.

If any hose (

fuel

oil

) lines are defective replace them

immediately.

If the battery cable is connected

incorrectly, electrical damage to the

generator will occur. Pay close

attention to the polarity of the

battery when connecting the

battery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fluid level between the specified

marks. Battery life will be shortened, if the fluid level are not

properly maintained. Add only distilled water when

replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables

are loose. Poor contact may result in poor starting or

malfunctions.

Always

keep the terminals firmly tightened.

Coating the terminals with an approved battery terminal

treatment compound. Replace battery with only

recommended type battery. The battery type used in this

generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of

the battery fluid is 1.28 (at 68° F). If the specific gravity

should fall to 1.245 or lower, it indicates that the battery is

dead and needs to be recharged or replaced.

Before charging the battery with an external electric source,

be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 37) are properly

connected to the battery terminals as shown below. The Red

Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal

of the battery.

CAUTION - BATTERY SERVICING SAFETY

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

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)

Manual Start-up

Procedure

Figure 42. MPEC Control Switch

(Manual Position)

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

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

Before Starting

Figure 39. Engine Enclosure Doors

1. Place the

main, G.F.C.I.,

and

aux.

circuit breakers

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

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

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).

CAUTION - LETHAL EXHAUST HAZARD

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.

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

the

MPEC Control Switch

in the MANUAL position to

start the engine (Figure 42).

Figure 41. Engine Speed Switch (Low)

Figure 43. Engine Speed Switch (High)

NEVER!

manually start the engine with the

main

GFCI

auxiliary

circuit breakers in the ON (closed) position.

WARNING - STARTING THE GENERATOR

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

LOW

”

(down) position.

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

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

Figure 47. Voltage Adjust Control Knob

Figure 48. Ammeter

(No Load)

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.

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.

Figure 46. Voltmeter

Figure 45. Frequency Meter (Hz)

5. The generator's frequency meter (Figure 45) should be

displaying the 60 cycle output frequency in HERTZ.

Figure 51. Engine

Tachometer Gauge

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.

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

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 49. Oil

Pressure Gauge

Figure 52. Main, Aux. and GFCI

Circuit Breakers (ON)

11. Place the

main

GFCI

, and

aux

. circuit breakers in the

ON position (Figure 52).

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.

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

1. Perform steps 1 through 5 in the

Before Starting

section.

2. Place the

engine speed switch

(Figure 54) in the HIGH

position

4. Continue operating the generator as outlined in the

Manual Start-up

Procedure

(start at step 5).

Figure 55. MPEC Control Switch (AUTO)

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.

NOTE

Starting (Auto Mode)

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.

DANGER - ELECTRICAL SYSTEM HAZARDS

When connecting the generator to a isolation (transfer)

switch, ALWAYS have power applied to the generator's

internal battery charger. This will ensure that the engine

will not fail due to a dead battery.

CAUTION - BACKUP GENERATOR USE

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.

WARNING - AUTO MODE MAINTENANCE

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

When starting generator in AUTO mode use the "

Manual

Start-up" procedure except where noted (see below).

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.

3. Place the

MPEC Control Switch

(Figure 55) in the AUTO

position

Figure 54. Engine Speed Switch (High)

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

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.

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.

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.

DCA-100SSVU — GENERATOR SHUT-DOWN PROCEDURES

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 56. Engine Speed Switch (Low)

NEVER stop the engine suddenly except in an emergency.

WARNING -

SHUTTING DOWN THE GENERATOR

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

DCA-100SSVU — MAINTENANCE

Service Daily

If the engine is operating in very

dusty

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

frequently

if these conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate

in the bottom of the tank. Occasionally inspect the fuel

tank for water contamination and drain the contents if

required.

During cold weather, the more empty volume inside the

tank, the easier it is for water to condense. This can be

reduced by keeping the tank full with diesel fuel.

General Inspection

Prior to each use, the generator should be cleaned and

inspected for deficiencies. Check for loose, missing or

damaged nuts, bolts or other fasteners. Also check for fuel,

oil, and coolant leaks. Use Table 14 as a general maintenance

guideline Engine Side (Refer to the Engine Instruction

Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the

heavy duty paper element with light spray of compressed

air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air

cleaner element is clogged, air intake restriction becomes

greater and the dust indicator signal shows RED meaning

the element needs changing or service. After changing the

air element, press the dust indicator button to reset the

indicator.

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

DCA-100SSVU — MAINTENANCE

Generator Storage

For longe term storage of the generator the following is

recommended:

Fill the fuel tank completely. Treat with a fuel stabilizer

if necessary.

Completely drain the oil from the crankcase and refill if

necessary with fresh oil.

Clean the entire generator, internal and external.

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

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block

and completely remove the tires.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open the

radiator cap while draining. Remove the overflow tank

and drain.

Check hoses for softening and kinks. Check clamps for

signs of leakage.

Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT

clean radiator core with any objects, such as a

screwdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant as recommended by the engine

manufaturer.

Close radiator cap tightly.

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.

Allow engine to

cool

when flushing out

radiator. Flushing the radiator while hot

could cause serious burns from water or

steam.

WARNING - BURN HAZARDS

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500

hours or so.

Loosen the drain plug at the lower top of the fuel filter.

Drain the fuel in the fuel body together with the mixed

water. DO NOT spill the fuel during disassembly.

Vent any air.

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.

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

DCA-100SSVU — MAINTENANCE

To ensure adequate starting

capability, always have power

applied to the generator's

internal battery charger

NOTE

Figure 56. Battery Charger &

Jacket Water Heater Power Connections

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).

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.

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.

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

DCA-100SSVU — TRAILER MAINTENANCE

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the

diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

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

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug

nuts. See Table 16 and Figure 59 for lug nut tightening

and sequence.

13. Axle - Indicates the maximum weight the axle can sup-

port in pounds, and the diameter of the axle expressed

in inches. Please note that some trailers have a double

axle. This will be shown as 2-6000 lbs., meaning two

axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension

used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

Trailer Maintenance

This section is intended to provide the user with generic

trailer service and maintenance information. The service and

maintenance guidelines referenced in this section refer to a

wide range of trailers.

Remember periodic inspection of the trailer will ensure safe

towing of the generator and will prevent personal injury and

damage to the equipment.

The definitions below describe some of the major components

of a typical trailer that would be used with the DCA-100SSVU

Whisperwatt

™

Generator.

1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans-

porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

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.

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

DCA-100SSVU — TRAILER MAINTENANCE

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

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat

properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

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.

Actuator

Hydraulic surge braking requires the installation of an actuator

at the tongue of the trailer. Remember the

surge

push

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.

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.diulf4todhtiwllif

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

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.

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.

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.

Figure 60. Major Suspension Components

DCA-100SSVU — TRAILER MAINTENANCE

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.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS

wear safety glasses when

removing or installing force fitted parts.

Failure to comply may result in serious

injury.

CAUTION - EYESIGHT HAZARD

stnemeriuqeReuqroTnoisnepsuS.71elbaT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SHACKLE BOLT

SPRING EYE BOLT

SNUG FIT ONLY

PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

BOLT ASSEMBLY

SHOULDER TYPE

SHACKLE BOLT

05-XAM03-NIM

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

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Figure 61. Wheel Lug Nuts

Tightening Sequence

DCA-100SSVU — TRAILER MAINTENANCE

NOTE

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.

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SBL-TF

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

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

DCA-100SSVU — TRAILER WIRING DIAGRAM

Figure 62. Trailer/Towing Vehicle Wiring Diagram

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

DCA-100SSVU — GENERATOR WIRING DIAGRAM

Figure 63. Generator Wiring Diagram

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

DCA-100SSVU — ENGINE WIRING DIAGRAM

Figure 64. Engine Wiring Diagram

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

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.

DCA-100SSVU — TROUBLESHOOTING (GENERATOR)

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

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?RVAevitcefeD .yrassecenfiecalpeR

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?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

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

DCA-100SSVU — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor

Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

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?ytridpukcipci

tengaM .pukcipcitengamnaelC

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

DCA-100SSVU — EXPLANATION OF CODE IN REMARKS COLUMN

OTE

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.

QTY. Column

Numbers Used - Item quantity can be indicated by a number,

a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts

that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold

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

Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to

describe the item can also be shown.

Assembly/Kit

- All items on the parts list with the same unique

symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

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.

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.

NO. Column

Unique Symbols - All items with same unique symbol

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

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

column.

Duplicate Item Numbers - Duplicate numbers indicate

multiple part numbers are in effect for the same general item,

such as different size saw blade guards in use or a part that

has been updated on newer versions of the same machine.

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.

Sample Parts List:

NO. PART NO. PART NAME QTY.REMARKS

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

2*WASHER, 1/4 IN. ...........

NOT SOLD SEPARATELY

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

MQ-45T ONLY

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

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

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.

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

DCA-100SSVU — SUGGESTED SPARE PARTS

Part number on this Suggested Spare Parts list

may supercede/replace the P/N shown in the text

pages of this book.

NOTE

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

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

DCA-100SSVU — GENERATOR ASSY.

GENERATOR ASSY.

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

DCA-100SSVU — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY.REMARK

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

1-1*FIELD ASSY. 1

1-2*8101070033 FAN 1

1-3*8101611004 COUPLING DISK 5

1-4*8101015003 BALANCING PLATE .................. 1 .................... PURCHASE ITEM 1-14 AS A SET

1-5*0012110030 HEX HEAD BOLT 8

1-6*0042510000 WASHER, LOCK 8

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

1-8*0601821349 RECTIFIER, PT 3610 2

1-9*0601822601 SURGE ABSORBER 1

1-10*8001020004 INSULATOR WASHER 1

1-11*8001020504 INSULATOR WASHER 1

1-12*0010110020 HEX HEAD BOLT 4

1-13*0040010000 WASHER, LOCK 4

1-14*0601000209 BALANCING WEIGHT KIT 1

1-15*0071906311 BEARING, 6311DDU C3 1

2 C0130200003 STATOR ASSY. 1

3 0845041804 GROMMET 2

4 8101315202 END BRACKET 1

5 8101350013 FIELD ASSY. EXCITER 1

6 0012110070 HEX HEAD BOLT 4

7 0042610000 WASHER, LOCK 4

8 0041210000 WASHER, FLAT 4

9 0010110035 HEX HEAD BOLT 6

10 0040010000 SPRING WASHER 6

11 0041210000 WASHER, FLAT 6

12 8101310014 COVER, BEARING 1

13 8131312014 GASKET, BEARING 1

14 8101333003 COVER, END BRACKET 1

15 0017106012 HEX HEAD BOLT 10

16 8101333003 COVER, END BRACKET 1

17 0010106030 HEX HEAD BOLT 2

18 0040006000 WASHER, LOCK 2

19 0041206000 PLAIN WASHER 2

20 M2163400003 COUPLING RING 1

21 0012110040 HEX HEAD BOLT 8

22 0042610000 WASHER, LOCK 8

23 0070506306 BEARING 1

24 0012810030 HEX HEAD BOLT 8

25 0012810030 HEX HEAD BOLT 12

26 8111332014 COVER, FAN 1

27 0600815000 NUT 1

28 0605000061 RUBBER SUSPENSION 2

29 0030016000 HEX NUT 2

29A 0040016000 WASHER, LOCK 2

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

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

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

DCA-100SSVU— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0602202545 CONTROLLER, ECU-9988N 1

2 0601831340 SWITCH 1

3 0601831395 ENGINE SPEED SWITCH 1

4 0602120096 TACHOMETER 1

5 0602122097 OIL PRESSURE GAUGE 1

6 0602123094 WATER TEMPERATURE GAUGE 1

7 0602121080 CHARGING AMMETER 1

8 0602125090 FUEL GAUGE 1

9 0601810141 PANEL LIGHT 1

10 0601831330 SWITCH, PANEL LIGHT 1

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

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

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

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

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

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

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

18 0601802149 FUSE, 10A 1

19 0601806671 FUSE, 15A 1

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)

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. (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

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

CONTROL BOX ASSY. (CONT.

S/N 7800001~7800129)

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

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

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

CONTROL BOX ASSY. (CONT.

S/N 7800001~7800129)

NO PART NO PART NAME QTY.REMARKS

38 M9220100004 SET SCREW 1

39 0080200007 SNAP RING 1

40 0601826031 RELAY, DC12V 1

41 0027104016 MACHINE SCREW 2

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

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

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

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

44 LY2DUS12VDC RELAY 1 REPLACES P/N 0601827656

44A 0601823109 RELAY BASE, PTF08A-E 1

4B 0601824400 RELAY CLIP, PYCA1 2

45 0601823768 RELAY, LY-2 DC12V 1

45A 0601823109 RELAY BASE, PTF08-E 1

45B 0601824400 RELAY CLIP, PYCA1 2

46 0027104020 MACHINE SCREW 4

47 0602202568 SPEED CONTROL UNIT 1

48 0027105016 MACHINE SCREW 4

49 0602120475 SPEED SENSOR 1

50 0016906020 HEX HEAD BOLT 1

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

52 V20405778 OIL PRESSURE SENSOR 1

53 V20412270 SENSOR TEMPERATURE 1

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)

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

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

NO PART NO PART NAME QTY.REMARKS

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

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

2 0601808822 CIRCUIT BREAKER, 3P 250A 1

3 0021005080 MACHINE SCREW 4

4 0601823863 RELAY UNIT 2

5 0027104016 MACHINE SCREW 4

6 0601820671 AUTOMATIC VOLTAGE REULATOR 1

7 0027105016 MACHINE SCREW 4

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

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

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

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

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

12 0027104016 MACHINE SCREW 2

13 0207004000 HEX NUT 2

14 0601826158 CAPACITOR, 0.01uF 1

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

16 0016906016 HEX HEAD BOLT 5

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

17A S2BG411 KNOB-HANDLE, BLACK

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

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

18 M3276600004 SPACER 8

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

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

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

21 M3260500004 SWITCH BOARD 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CONTROL BOX ASSY. (CONT.

S/N 7800130~AND ABOVE)

NO PART NO PART NAME QTY.REMARKS

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

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

38 M9220100004 SET SCREW 1

39 0080200007 SNAP RING 1

40 0601826031 RELAY, DC12V 1

41 0027104016 MACHINE SCREW 2

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

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

44 0601827656 RELAY, LY-2D DC12V 1

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

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

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

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

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

46 0027104020 MACHINE SCREW 4

47 0602202568 SPEED CONTROL UNIT 1

48 0027105016 MACHINE SCREW 4

49 0602120475 SPEED SENSOR 1

50 0016906020 HEX HEAD BOLT 1

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

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

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

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

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

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

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

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

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

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

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

58 V20405778 OIL PRESSURE SENSOR 1

59 V20412270 SENSOR TEMPERATURE 1

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

DCA-100SSVU— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

DCA-100SSVU— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY.REMARKS

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

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

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

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

2 M3303200204 ENGINE FOOT 1

3 M3303200304 ENGINE FOOT 1

4 0012112040 HEX HEAD BOLT 4

5 0030312000 HEX NUT 4

6 0042512000 WASHER, LOCK 4

7 0605000450 RUBBER SUSPENSION 2

8 0030012000 HEX NUT 2

9 0040012000 WASHER, LOCK 2

10 M3310201104 RADIATOR BRACKET 2

11 0016908020 HEX HEAD BOLT 4

12 M3310200814 SEAL BRACKET 1

13 0283202350 SEAL RUBBER 1

14 0222900510 SEAL RUBBER 2

15 0016906020 HEX HEAD BOLT 6

16 0602022563 ADAPTER 1

17 0802022561 90 DEG. ELBOW 1

18 0803306590 CONNECTOR 1

19 0603300285 ROCKNUT 1

20 0605511395 VALVE 1

21 0603306395 HOSE JOINT 1

22 0802021070 CAP 1

23 0269200800 DRAIN HOSE 1

24 M3310600104 DRAIN JOINT 1

25 0199800800 DRAIN HOSE 1

26 0193101200 OVER FLOW HOSE 1

27 V978515 V-BELT ALTERNATOR 1

28 V20405794 ALTERNATOR 1

29 V978750 V-BELT, FUEL PUMP 1

30 V20412278 HOSE RADIATOR, UPPER 1

31 V20412279 HOSE RADIATOR 1

32 V20405779 MONITOR, OIL PRESSURE 1

33 V20543720 TEMPERATURE SENSOR UNIT 1

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

DCA-100SSVU— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK

2-WHITE 6-CATERPILLAR YELLOW

3-SPECTRUM GREY 7-CATO GOLD

4-SUNBELT GREEN 8-RED

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

DCA-100SSVU— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY.REMARKS

1 M3230700003 TERMINAL PANEL 1

2 M9220100304 OUTPUT TERMINAL BOLT 5

3 M9220100404 TIE BOLT 5

4 0039316000 HEX NUT 10

5 0040016000 WASHER, LOCK 15

6 0041416000 WASHER, FLAT 20

7 0016908035 HEX HEAD BOLT 5

8 M3238100103 TERMINAL COVER 1

9 M3236100104 OUTPUT WINDOW 1

10 0606010040 HINGE 2

11 0027103010 MACHINE SCREW 4

11A 0030003000 HEX NUT 4

11B 0041203000 WASHER, FLAT 4

12 0027103010 MACHINE SCREW 4

12A 0030003000 HEX NUT 4

13 0016906020 HEX HEAD BOLT 2

14 0016906016 HEX HEAD BOLT 4

15 M3236400004 CABLE OUTLET COVER 1

16 M3236300004 SUPPORTER, CABLE OUTLET COVER 1

17 0016906020 HEX HEAD BOLT 6

18 0601808803 CIRCUIT BREAKER, 120V,1P 20A 2

19 0601808804 CIRCUIT BREAKER, 250V, 2P 50A 3

20 M1260700304 BREAKER FITTING COVER 1

20-1 0222100150 CUSHION RUBBER 1

21 0016906020 HEX HEAD BOLT 2

22 0601812598 RECEPTACLE, 125V 20A X 2 2

23 0601812538 RECEPTACLE, CS6369 250V 50A 2

24 0027104016 MACHINE SCREW 10

24A 0207004000 HEX NUT 10

25 M3236100213 TERMINAL COVER 1

26 0010112045 HEX HEAD BOLT 2

27 0041212000 PLAIN WASHER 2

28 M9310200004 STAY RUBBER 2

29 0030012000 HEX NUT 2

30 0603306775 BIND PLUG 2

31 0027104016 MACHINE SCREW 4

32 0601815194 TERMINAL 1

33 0027104016 MACHINE SCREW 2

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

DCA-100SSVU — ACTUATOR ASSY.

ACTUATOR ASSY.

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

DCA-100SSVU — ACTUATOR ASSY.

ACTUATOR ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0602150070 ACTUATOR 1

2 M3354200004 ACTUATOR BRACKET 1

3 0021108020 FLAT HEAD SCREW 2

4 0014208035 HEX SOCKET HEAD CAP SCREW 1

4A 0030008000 HEX NUT 1

4B 0040008000 WASHER, LOCK 1

4C 0041208000 WASHER, FLAT 2

5 0014208035 HEX SOCKET HEAD CAP SCREW 1

5A 0041208000 WASHER, FLAT 1

6 M3354300404 THROTTLE THREAD 1

7 0602180290 ROD END 2

8 0038202000 HEX NUT 2

9 M3351800004 COLLAR 1

10 0041208000 PLAIN WASHER 3

11 0010106040 HEX HEAD BOLT 1

12 0030006000 HEX NUT 2

13 0041206000 WASHER, FLAT 3

14 0017106025 HEX HEAD BOLT 1

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

DCA-100SSVU— BATTERY ASSY.

BATTERY ASSY.

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

DCA-100SSVU— BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0602220196 BATTERY 1

2 M9310500404 BATTERY SHEET 1

3 M9103000504 BATTERY BAND 1

4 0602220921 BATTERY BOLT SET 2

5 0040006000 SPRING WASHER 2

6 M3346900804 BATTERY CABLE 1

7 M3346900604 BATTERY CABLE 1

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

9 0017112025 HEX HEAD BOLT 1

9A 0040512000 TOOTHED WASHER 1

10 0017110020 HEX HEAD BOLT 1

10A 0040510000 TOOTHED WASHER 1

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

DCA-100SSVU— MUFFLER ASSY.

MUFFLER ASSY.

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

DCA-100SSVU— MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0602300167 MUFFLER 1

2 0016910025 HEX HEAD BOLT 4

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

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

4 0602320198 GASKET 1

5 M3333200004 GASKET 1

6 0017110040 HEX HEAD BOLT 4

7 0017110040 HEX HEAD BOLT 4

8 M3330400304 COVER 1

9 M3330400403 BRACKET 1

10 0016908020 HEX HEAD BOLT 4

11 0602326061 U-BOLT SET 1

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

DCA-100SSVU— FUEL TANK ASSY.

FUEL TANK ASSY.

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

DCA-100SSVU— FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY.REMARKS

1 M3363001002 FUEL TANK 1

1-1 0605505070 CAP, FUEL TANK 1

2 M3363200204 TANK BAND 2

3 M9310500104 SUPPORTER SHEET 4

4 0016908020 HEX HEAD BOLT 2

5 0207308000 HEX NUT 2

6 0222100660 RUBBER SHEET 2

7 M9200000003 DRAIN JOINT 1

8 M9200200004 DRAIN BOLT 1

9 0150000018 O RING 1

10 0016906020 HEX HEAD BOLT 2

11 M1363400104 DRAIN HOSE 1

12 0605515198 HOSE BAND 2

13 0602042266 WATER SEPARATOR 1

13A 0602042766 ELEMENT 1

14 0017110040 HEX HEAD BOLT 2

15 0602022567 90 DEG. ELBOW 2

16 0602022980 SWIVEL 2

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

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

19 0191400770 SUCTION HOSE 1

20 0191302900 RETURN HOSE 1

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

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

22 0605515109 HOSE BAND 2

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

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

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

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

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

DCA-100SSVU— ENCLOSURE ASSY.

ENCLOSURE ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK

2-WHITE 6-CATERPILLAR YELLOW

3-SPECTRUM GREY 7-CATO GOLD

4-SUNBELT GREEN 8-RED

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

DCA-100SSVU— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO PART NO PART NAME QTY.REMARKS

1 M3413001612 BASE 1

2 M1413400004 UNDER COVER 1

3 0016908020 HEX HEAD BOLT 2

4 M3423001012 FRONT FRAME 1

4A M3493105713 ACOUSTIC SHEET 1

5 0016910025 HEX HEAD BOLT 6

6 M3423200104 COVER, FRONT FRAME 1

6A M3493100304 ACOUSTIC SHEET 1

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

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

8 M3433000712 CENTER FRAME 1

8A M3493200004 ACOUSTIC SHEET 1

9 0010114040 HEX HEAD BOLT 12

9A 0030014000 HEX NUT 12

9B 0040014000 WASHER, LOCK 24

9C 0041214000 WASHER, FLAT 24

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

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

10A M3493300204 ACOUSTIC SHEET 1

11 0016910025 HEX HEAD BOLT 4

11A 0040510000 TOOTHED WASHER 1

12 M3443300203 REAR COVER 1

13 M3443300903 DUCT, REAR COVER 2

13A M3493302603 ACOUSTIC SHEET 1

14 0207006000 HEX NUT 12

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

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

16 M3443200113 REAR DOOR 1

17 M3443600104 WINDOW PLATE 1

18 0207306000 HEX NUT 10

18A 0041206000 WASHER, FLAT 10

19 M9113000002 DOOR HANDLE ASSY. 1

20 0021806016 MACHINE SCREW 4

20A 0030006000 HEX NUT 4

21 M9110100204 HINGE 2

21A M9116100004 WASHER 2

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

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

23 M9310000004 BLIND PLUG 2

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

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

24A M3493502703 ACOUSTIC SHEET 1

25 M3463200403 ROOF PANEL 1

25A M3493502803 ACOUSTIC SHEET 1

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

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

THE SERIAL NUMBER MAY BE REQUIRED.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK

2-WHITE 6-CATERPILLAR YELLOW

3-SPECTRUM GREY 7-CATO GOLD

4-SUNBELT GREEN 8-RED

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

DCA-100SSVU— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO PART NO PART NAME QTY.REMARKS

26 M3463500404 OVER COVER, FRONT FRAME 1

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

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

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

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

30 M3453200512 SPLASHER PANEL 1

30A M3493411904 ACOUSTIC SHEET 1

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

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

32 M3453001813 HEX HEAD BOLT 2

33 M3453001813 SIDE DOOR 1

33A M3493411414 ACOUSTIC SHEET 1

34 M3453002403 SIDE DOOR 1

34A M3493411414 ACOUSTIC SHEET 1

35 M3453002003 SIDE DOOR 1

35A M3493411604 ACOUSTIC SHEET 1

36 M3453002113 SIDE DOOR 1

36A M3493411714 ACOUSTIC SHEET 1

37 M3453302103 DUCT 1

37A M3493411314 ACOUSTIC SHEET 1

38 M3453302003 DUCT 1

39 M3453301903 DUCT 1

39A M3493411514 ACOUSTIC SHEET 1

40 M3453302203 DUCT 1

40A M3493411814 ACOUSTIC SHEET 1

41 0207006000 HEX NUT 34

42 0016906016 HEX HEAD BOLT 5

43 M9113000002 DOOR HANDLE ASSY. 4

44 0021806016 MACHINE SCREW 16

44A 0030006000 HEX NUT 16

45 M3453700314 GUTTER 1

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

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

47 M9110100204 HINGE 4

47A M9116100004 WASHER 4

48 M9110100304 HINGE 4

48A M9116100004 WASHER 4

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

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

50 0601850097 STOPPER 8

51 0027208025 MACHINE SCREW 8

52 M9310000004 BLIND PLUG 8

53 0016908020 HEX HEAD BOLT 1

53A 0040508000 TOOTHED WASHER 1

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

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

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

DCA-100SSVU— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

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

DCA-100SSVU— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO PART NO PART NAME QTY.REMARKS

1 0228900785 SEAL RUBBER 3

2 0229200725 SEAL RUBBER 1

3 0228901020 SEAL RUBBER 2

4 0228900990 SEAL RUBBER 4

5 0228901060 SEAL RUBBER 4

6 0228900470 SEAL RUBBER 2

7 0229201100 SEAL RUBBER 4

8 0229201040 SEAL RUBBER 1

9 0228800630 SEAL RUBBER 1

10 0228800970 SEAL RUBBER 2

11 0228800590 SEAL RUBBER 1

12 0228100665 SEAL RUBBER 1

13 0228100370 SEAL RUBBER 1

14 0228100300 SEAL RUBBER 1

15 0228100365 SEAL RUBBER 1

16 0228100280 SEAL RUBBER 1

17 0228100070 SEAL RUBBER 1

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

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

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

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO PART NO PART NAME QTY.REMARKS

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

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

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

CONTROL PANEL, BOX & OPERATING PANEL GROUP

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

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

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

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

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

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

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

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

ENGINE & RADIATOR GROUP

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

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

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

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

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

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

OUTPUT TERMINAL GROUP

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

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

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

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

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

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

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

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

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

BATTERY GROUP

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

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

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

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

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

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

DCA-100SSVU— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO PART NO PART NAME QTY.REMARKS

MUFFLER GROUP

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

FUEL TANK GROUP

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

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

ENCLOSURE GROUP

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

8-2 0600500090 EMBLEM 1

9-2A 0021106015 MACHINE SCREW 2

8-3 M3560100003 STRIPE 1

8-4 M3560100103 STRIPE 2

8-5 M3560101904 STRIPE 2

8-6 M3560100404 STRIPE 2

8-7 M3560101704 STRIPE 1

8-8 M3560101804 STRIPE 1

8-9 M3560100604 STRIPE 2

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

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed

manifest has been obtained from the carrier,

and any claim for shortage or damage must be

settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit

will be allowed, subject to the following provi-

sions:

1. A Returned Material Authorization must

be approved by Multiquip prior to ship-

ment.

2. To obtain a Return Material Authorization,

a list must be provided to Multiquip Parts

Sales that defines item numbers, quanti-

ties, 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 request-

ing the RMA.

3. A copy of the Return Material Authoriza-

tion must accompany the return shipment.

4. Freight is at the sender’s expense. All

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

dition, in the original Multiquip package (if

any), and with Multiquip part numbers

clearly marked.

6. The following items are not returnable:

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

price book and shows as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

and other rubber parts) that were pur-

chased more than six months prior to

the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notified of any

material received that is not acceptable.

8. 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 re-

turned to the sender at his expense.

9. 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.

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 spe-

cific date and all orders received on or after that

date will be billed at the revised price. Rebates

for price declines and added charges for price

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

Effective: October 1, 2002

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

NOTE PAGE

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

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

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

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

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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