Multiquip Portable Generator DCA 100SSJU User Manual

PARTS AND OPERATION MANUAL

Table of Contents

MQ POWER

DCA-100SSJU

WHISPERWATT

GENERATOR

(Standard)

PARTS LIST NO. M3870300174

S/N UP TO 7400295-100SSJU

S/N FROM 7400296~100SSJU2

Revision #2 (05/03/01)

MULTIQUIPINC.

18910 WILMINGTON AVE.

PARTS DEPARTMENT:

800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

800-421-1244

SERVICE DEPARTMENT:

800-835-2551

FAX:310-537-3927

FAX:310-638-8046

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

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Table of Contents

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HANDWHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

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

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

TrailerWiring Diagram ................................................ 18

Trailer Troubleshooting (Electric Brakes) .................... 19

TrailerTroubleshooting (Hydraulic Brakes) ................. 20

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

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

EngineTroubleshooting ......................................... 56-57

Generator/EngineTroubleshooting ............................. 58

MPECTroubleshooting .............................................. 59

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

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

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

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

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

Engine Operating Panel Assembly ........................ 72-73

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

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

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

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

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

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

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

MQ POWER DCA-100SSJU

AC GENERATOR

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

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

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

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

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

Engine Operating Panel w/key............................. 30-31

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

OutputTerminal Panel Overview ........................... 34-41

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

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

Load Application ........................................................ 48

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

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

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

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

NOTE

Specification and part number

are subject to change without

notice.

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

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Table of Contents

PARTS ORDERING PROCEDURES

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

Express account number)*

•

Airborne Express*

•

Truck or parcel post

•

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

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers

and are received by fax qualify for the following extra

discounts:

Number of

line items ordered

Additional Discount

1-9 items

10+ items**

only

der

ed or

For

Get special freight allowances

when you order 10 or more

line items via FAX!**

Now! Direct TOLL-FREE access

to our Parts Department!

■

UPS Ground Service at no charge for freight

■

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

Toll-free nationwide:

800-421-1244

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.

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

800/6-PARTS-7 • 800-672-7877

Fax order discount and UPS special programs revised June 1, 1995

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

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Table of Contents

RULES FOR SAFE OPERATION

CAUTION:

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engine or generator.

Failure to follow instructions in this manual

may lead to serious injury or even death!

This equipment is to be operated by trained

and qualified personnel only!This equipment

is for industrial use only.

The following safety guidelines should always be used when

operating the DCA-100SSJU portable generator:

■

High Temperatures – Allow the engine to cool before

adding fuel or performing service and maintenance

functions. Contact with hot components can cause serious

burns.

GENERAL SAFETY

■DONOToperateorservicethisequipmentbefore

reading this entire manual.

■

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

■

This equipment should not be operated by

persons under 18 years of age.

is restricted it will cause

serious damage to the

generator or engine and

may cause injury to

people. The generator

■

NEVER operate this equipment without proper

protective clothing, shatterproof glasses, steel-

toed boots and other protective devices

required by the job.

engine gives off DEADLY

carbon monoxide gas.

■

NEVER operate this equipment when not feeling

well due to fatigue, illness or taking medicine.

CAUTION

■

NEVER operate this equipment under the

Always refuel in a well-ventilated area,

away from sparks and open flames.

influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment. Damage

to the equipment and/or injury to user may result.

■

Always use extreme caution when

working with flammable liquids. When

refueling, stop the engine and allow it

to cool. DO NOT smoke around or near

the machine. Fire or explosion could

result from fuel vapors, or if fuel is spilled

on a hot engine.

■

Manufacturer does not assume responsibility for any

accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts

■

NEVER operate the generator in an

before starting.

explosive atmosphere or near combustible

materials. An explosion or fire could result

causing severe bodily harm or even

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

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

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Table of Contents

RULES FOR SAFE OPERATION

CAUTION

DO NOT touch or open any of the below

mentioned components while the

generator is running. Always allow

sufficient time for the engine and generator

to cool before performing maintenance.

■

NEVER touch output terminals during operation. This is

Radiator

extremely dangerous. Always stop the machine when

1. Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water

to gush out of the radiator, causing severe scalding to

any persons in the general area of the generator.

contact with the output terminals is required.

CAUTION

■

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.

2. Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant to gush

out of the coolant drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

CAUTION

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

plug while the engine is hot will result in hot oil to gush

out of the oil drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

■

Never use damaged or worn cables when connecting

power tools or equipment to the generator. Make sure

power connecting cables are securely connected to the

generator’s output terminals, insufficient tightening of the

terminal connections may cause damage to the generator

and electrical shock.

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

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RULES FOR SAFE OPERATION

Battery

■NEVER Run engine without air filter. Severe engine

damage may occur.

CAUTION

■

Always service air cleaner frequently to prevent carburetor

Never over fill the battery with water above

the upper limit.

malfunction.

■Always disconnect the battery before performing service

on the generator.

■

Always be sure the operator is familiar with proper safety

precaution s and operations techniques before using

generator.

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. Use

the following guidelines when handling the battery:

■

Always store equipment properly when not in use.

Equipment should be stored in a clean, dry location out of

the reach of children.

■

DO NOT leave the generator running in the manual mode

unattended.

■

DO NOT allow unauthorized people to operate this

equipment.

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

■

Always read, understand, and follow procedures in

that the battery may explode.

Operator’s Manual before attempting to operate equipment.

2. DO NOT expose the battery to open flames, sparks,

cigarettes etc. The battery contains combustible gases

and liquids. If these gases and liquids come in contact

with a flame or spark, an explosion could occur.

■

Refer to the John Deere Engine Owner's Manual for

engine technical questions or information.

Loading and Unloading (Crane)

■

Before lifting, make sure the generator's lifting hook is

secure and that there is no apparent damage to the

generator itself (loose screws, nuts and bolts). If any

part is loose or damaged, please take corrective action

before lifting.

3. Always keep the battery charged. If the battery is not

charged a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good

working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment,

to avoid risk of a dangerous concentration of combustible

gases.

■

Always drain fuel prior to lifting.

Always make sure crane or lifting device has been

properly secured to the hook of guard frame on generator.

6. In case the battery liquid (dilute sulfuric acid) comes in

contact with clothing or skin, rinse skin or clothing

immediately with plenty of water.

■

NEVER lift the machine while the engine is running.

Use adequate lifting cable (wire or rope) of sufficient

strength.

7. In case the battery liquid (dilute sulfuric acid) comes in

contact with your eyes, rinse eyes immediately with

plenty of water, then contact the nearest doctor or hospital,

and seek medical attention.

■

When lifting the generator, always use the balanced

center-point suspension hook and lift straight upwards.

NEVER allow any person or animal to stand underneath

the machine while lifting.

When loading the generator on a truck, be sure to use

the front and back frame bars as a means to secure the

generator during transport.

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

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RULES FOR SAFE OPERATION

Transporting

Maintenance Safety

■

Always shutdown engine before transporting.

■

NEVER lubricate components or attempt service on a

running machine.

Tighten fuel tank cap securely.

■

Always allow the machine a proper amount of time to

cool before servicing.

Drain fuel when transporting generator over long distances

or bad roads.

■

Keep the machinery in proper running condition.

■

Always tie-down the generator during transportation by

securing the generator.

Fix damage to the machine immediately and always

replace broken parts.

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. See page 10 for basic towing procedures.

■

Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant,

fuel, and fuel filters.

Emergencies

■

DO NOT use plastic containers to dispose of hazardous

waste.

■

Always know the location of the nearest fire extinguisher

and first aid kit. Know the location of the nearest telephone.

Also know the phone numbers of the nearest ambulance,

doctor and fire department.

DO NOT pour waste, oil, coolant or fuel directly onto the

ground, down a drain or into any water source.

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

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Table of Contents

DCA-100SSJU —TOWING RULES FOR SAFE OPERATION

Towing Safety Precautions

■

ALWAYS attach trailer’s safety chain to bumper of towing

vehicle.

CAUTION :

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

Check with your county or state safety

towing regulations department before towing

your generator.

■

The maximum speed for highway towing is 45 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 10 MPH or less depending on type of

terrain.

To reduce the possibility of an accident

while transporting the generator on public roads, always

make sure the trailer (Figure 1) that supports the generator

and the towing vehicle are in good operating condition and

both units are mechanically sound.

■

Place chocked blocks underneath wheel to prevent

rolling, while parked.

Place support blocks underneath the trailer’s bumper to

prevent tipping, while parked.

The following list of suggestions should be used when towing

your generator:

Use the trailer’s hand winch to adjust the height of the

trailer, then insert locking pin to lock wheel stand in place,

while parked.

■

Make sure the hitch and coupling of the towing vehicle

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

weight rating" (GVWR).

■

Avoid sudden stops and starts. This can cause skidding,

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

improve gas milage.

■

ALWAYS inspect the hitch and coupling for wear.NEVER

tow a trailer with defective hitches, couplings, chains

etc.

■

Avoid sharp turns to prevent rolling.

■

Check the tire air pressure on both towing vehicle and

trailer. Also check the tire tread wear on both vehicles.

Remove wheel stand when transporting.

DO NOT transport generator with fuel in tank.

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

Figure 1. Generator with Trailer

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

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DCA-100SSJU —TRAILER-SAFETY GUIDELINES

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

CAUTION:

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

ALWAYS make sure the trailer is in good

operating condition. Check the tires for

proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

(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

Explanation of Chart:

axle.

This section is intended to provide the user with trailer ser-

vice and maintenance information. The service and main-

tenance guidelines referenced in this section apply a wide

range of trailers. Remember periodic inspection of the trailer

will ensure safe towing of the equipment and will prevent

damage to the equipment and personal injury.

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

must match the size of the tire.

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

Always use a torque wrench to tighten down the lug

nuts. SeeTable 4 and Figure 5 for lug nut tightening and

sequence.

It is the purpose of this section to cover the major mainte-

nance components of the trailer. The following trailer com-

ponents will be discussed in this section:

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

port in pounds, and the diameter of the axle expressed

in inches (see Table 3 on page 17). Please not that

some trailers have a double axle. This will be shown as

2-6000 lbs., meaning two axles with a total weight ca-

pacity of 6000 pounds.

Brakes

Tires

Lug NutTorquing

Suspension

Electrical

14. Suspension - Protects the trailer chassis from shock

transmitted through the wheels. Types of suspension

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

BrakeTroubleshootingTables

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle. See page 16 for

proper wiring connections.

Use the following definitions while reading Table 1.

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

the equipment in use. Fuel cells must be empty when

transporting equipment.

16. Application - Indicates which units can be employed

on a particular trailer.

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 - This measurement is from the ball

hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to

fender.

6. Jack Stand - Trailer support device with maximum

pound requirement from the tongue of the trailer.

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

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Table of Contents

DCA-100SSJU —TRAILER-SPECIFICATIONS

Table 1. Specifications

MODEL

APPLICATION

FUEL

CELL

BRAKE

SYSTEM

GVWR

FRAME

LENGTH

FRAME

WIDTH

JACK

STAND

TRLR-10-15

TRLR-10X

TLG-12, DCA15,

TLW-300

1900LBS

2200LBS

2700LBS

2990LBS

7000LBS

10000LBS

11160LBS

14000LBS

18000LBS

30000LBS

96"

85"

50"

42"

800LB.

FULL TILT WHEEL

TLG-12, DCA15,

TLW-300

800LB.

FULL TILT WHEEL

TRLR-10XF

TRLR-225W

BLW-400

TLG-12, DCA15,

TLW-300

51 GAL

800LB.

FULL TILT WHEEL

DCA-10

800LB.

FULL TILT WHEEL

BLW-400

ELECTRIC

W/MAST 154"

W/O 124"

55"

(78" TALL)

800LB.

FULL TILT WHEEL

TRLR-15XF

TRLR-50X

DCA-15

41 GAL

124"

120"

186"

138"

190"

186"

204"

222"

238"

384"

55"

66"

77"

66"

76"

77"

84"

83"

96"

800LB.

FULL TILT WHEEL

DCA-25

800LB.

FULL TILT WHEEL

TRLR-50XF

TRLR-25SBT

TRLR-70W

TRLR-70X

DCA-25

41 GAL

800LB.

FULL TILT WHEEL

DCA-25

800LB.

FULL TILT WHEEL

DCA-45, -60, 70

DCA-100, 125

SURGE

2000LB.

FLAT PAD

OPT

SURGE

2000LB.

FLAT PAD

TRLR-70XF

TRLR-100XF

TRLR-85/125

TRLR-150XF

TRLR-220XF

TRLR-300XF

TRLR-400XF

TRLR-600XF

TRLR-800SX

53 GAL

150 GAL

145 GAL

200 GAL

250 GAL

350 GAL

550 GAL

SURGE

2000LB.

FLAT PAD

HYDRAULIC SURGE

HYDRAULIC

HYDRAULIC SURGE

ELECTRIC

AIR

2000LB.

FLAT PAD

DCA-85, 100,

125

2000LB.

FLAT PAD

DCA-150, 180

5000 LB.

FLAT PAD

DCA-220

5000 LB.

FLAT PAD

DCA-300

5000 LB.

FLAT PAD

DCA-400

5000 LB.

FLAT PAD

DCA-600, 800

5000 LB.

FLAT PAD

AIR

5000 LB.

FLAT PAD

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

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DCA-100SSJU —TRAILER-SPECIFICATIONS

Table 1. Specifications (Con't)

MODEL

COUPLER

TIRES

WHEELS

AXLE

HUBS SUSPENSION

ELECTRICAL

TRLR-10-15W

2" BALL CLASS

2 ADJUSTABLE

175-13C

13"X4.50"

2200# 2X2

5 LUG

6 LUG

8 LUG

3 LEAF

Q FLEX

3 LEAF

4 LEAF

5 LEAF

7 LEAF

Q FLEX

7 LEAF

AIR-RIDE

4 WIRE LOOM W/

4 POLE FLAT

TRLR-10X

TRLR-10XF

TRLR-225W

BLW 400

2"BALL CLASS

2 ADJUSTABLE

175-13C

13"X4.5"

13X4.5"

13 X 4.5"

13"X4.50"

14"X5"

2200#2X2

3500# 2-1/2"

4 POLE FLAT

2"BALL CLASS

2 ADJUSTABLE

2"BALL CLASS

2 ADJUSTABLE

175-13B

2"BALL CLASS

2 ADJUSTABLE

175-13C

TRLR-15XF

TRLR-50X

TRLR-50XF

TRLR-70W

TRLR-70X

TRLR-70XF

2" BALL CLASS

B78-13LRC

4 POLE RUBBER

FLAT

3500lbs.

2-3/8"

4 POLE RUBBER

FLAT

3500lbs.

2-3/8"

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

3500lbs.

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

14"X5"

3500lbs

4 POLE RUBBER

FLAT

2" BALL CLASS

3" ADJUSTABLE

205-14C

BIAS (4)

14"X5"

3500lbs.

4 POLE RUBBER

FLAT

TRLR-100XF ADJUSTABLE 2-5/6

205-15C

BIAS (4)

14"X5.5"

14"x6"

3500lbs

4 WIRE LOOM

6 WIRE LOOM

OPT 3" EYE

TRLR-85/125 ADJUSTABLE 2-5/6

ST225/75R15D

RADIAL (4)

(2)-6000lbs

(2)-7000lbs

(2)-6000lbs

(3)-7000lbs.

(3)-10000lbs

OPT 3" EYE

TRLR-150XF

TRLR-220XF

TRLR-300XF

TRLR-400XF

TRLR-600XF

TRLR-800AR

3" BALL EYE

750-16 E

BIAS (4)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(4)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(6)

16"X7"

3" EYE

ADJUSTABLE

ST235/85R16E

RADIAL(6)

16"X7"

5TH WHEEL

ST215/75R17.5H

RADIAL (8)

16"X7"

ST215/75R17.5H

RADIAL (8)

16"X7"

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

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DCA-100SSJU —TRAILER BRAKING SYSTEM

Brakes

synchronization between the tow vehicle and the trailer

If your trailer has a braking system, the brakes should be

inspected the first 200 miles of operation. This will allow

the brake shoes and drums to seat properly. After the first

200 mile interval, inspect the brakes every 3,000 miles. If

driving over rough terrain, inspect the brakes more

frequently.

being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be

made, the trailer brakes should be burnished-in by applying

the brakes 20-30 times with approximately a 20 m.p.h.

decrease in speed, e.g. 40 m.p.h. to 20 m.p.h.. Allow ample

time for brakes to cool between application. This allows

the brake shoes to slightly be seated into the brake drum

surface.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to

hydraulic brakes. The basic difference is that hydraulic

brakes are actuated by an electromagnet.

Figure 2 displays the major electric brake components that

will require inspection and maintenance. Please inspect

these components as required. Refer toTable 5 for electric

brake troubleshooting guidelines.

Listed below are some of the advantages that electric

brakes have over hydraulic brakes:

An electric brake system can be manually adjusted to

provide the corrected braking capability for varying road

and load conditions.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

An electric brake system can be modulated to provide

more or less braking force, thus easing the brake load

on the towing vehicle.

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.

An electric brake system has very little lag time between

the time the vehicle’s brakes are actuated and the

trailer’s brakes are actuated.

4. With a screwdriver or standard adjusting tool, rotate

the star wheel of the adjuster assembly to expand the

brake shoes.

An electric brake system can provide an independent

emergency brake system.

5. Adjust the brake shoes outward until the pressure of

the lining against the wheel drum makes the wheel

difficult to turn.

Road testing is necessary in order to properly synchronize

the towing vehicle’s braking to the trailer’s braking. Brake

lockup, grabbiness, or harshness is due to lack of

6. 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 6 on the remaining brakes.

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

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DCA-100SSJU —TRAILER BRAKING SYSTEM

Figure 2. Electrical Brake Components

Figure 3 below displays the major hydraulic/air/surge brake

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special

attention with the exception of routine maintenance such

as shoe and lining replacement. These brakes can be

adjusted in the same manner as electric brakes. Brake

lines should be periodically checked for cracks, kinks, or

blockage.

components that will require inspection and maintenance.

Inspect these components as required using steps 1

through 6 as referenced in the electric brake adjustments

section. Reference Table 6 for hydraulic brake

troubleshooting guidelines.

Figure 3. Hydraulic Brake Components

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

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DCA-100SSJU —TRAILERTIRES & SUSPENSION

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing

the trailer wheels it is important the wheels, tires, and axle

are properly matched.

CAUTION:

DO NOT attempt to repair or modify a

wheel. DO NOT install an inner tube to

correct a leak through the rim. If the

rim is cracked, the air pressure in the

inner tube may cause pieces of the rim

to explode (break off) with great force and cause serious

eye or bodily injury.

Suspension

The leaf suspension springs and associated components

(Figure 4) should be visually inspected every 6,000 miles

for signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 3.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in

preserving tire life. Pressure should be checked cold before

operation. DO NOT bleed air from tires when they are hot.

Check inflation pressure weekly to insure the maximum

tire life and to prevent premature tread wear.

Table 2 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing

or installing force fitted parts. Failure to

comply may result in serious injury.

Figure 4. Suspension Components

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DCA-100SSJU —TRAILERTIRES & SUSPENSION

Table 3. Suspension Torque Requirements

Item

Torque (Ft.-Lbs.)

3/8" U-BOLT

7/16" U-BOLT

1/2" U-BOLT

MIN-30 MAX-35

MIN-45 MAX-60

SHACKLE BOLT

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN NUT-BOLT ASSEMBLY

PARTS MUST ROTATE FREELY.

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

MIN-30 MAX-50

Lug NutTorque 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 5. DO

NOT torque the wheel lug nuts all the way down. Tighten

each lug nut in 3 separate passes as defined by Table

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically for continued safe

operation.

Table 4. Tire Torque Requirements

Wheel Size

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

12"

13"

14"

15"

16"

20-25

35-40

50-60

50-65

90-120

Figure 5. Lug Nut Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

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

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DCA-100SSJU —TRAILERWIRING DIAGRAMS

NOTE:

LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

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DCA-100SSJU —TRAILER-BRAKETROUBLESHOOTING

Table 5. Electric Brake Troubleshooting

SYMPTOM

POSSIBLE CAUSE

ANY OPEN CIRCUITS OR BROKEN WIRES?

ANY SHORT CIRCUITS?

SOLUTION

NO BRAKES OR INTERMITTENT BRAKES

FIND AND CORRECT

TEST AND CORRECT

FIND AND REPAIR

FIND AND SECURE

CLEAN OR REPLACE

FAULTY CONTROLLER

ANY LOOSE CONNECTIONS?

IS THE GROUND WIRE SECURE?

WEAK BRAKES OR BRAKES PULL TO ONE SIDE

IS THERE GREASE OR OIL ON MAGNETS OR LININGS?

IS THE CONNECTIONS CORRODED?

CLEAN AND CORRECT CAUSE OF

CORROSION

IS THE BRAKE DRUMS SCORED OR GROOVED

MACHINE OR REPLACE

IS THE BRAKES SYNCHRONIZED?

CORRECT. (SEE PG 8 FOR

SYNCHRONIZING

)

LOCKING BRAKES

NOISY BRAKES

IS THE BRAKE COMPONENTS LOOSE

BENT OR BROKEN?

REPLACE COMPONENTS

REPLACE

LUBRICATE

REPLACE AND CORRECT

ADJUST

IS THE BRAKE DRUMS OUT-OF-ROUND?

IS THE SYSTEM LUBRICATED?

IS THE BRAKE COMPONENTS CORRECT?

DRAGGING BRAKES

IS THE BEARINGS OF THE WHEEL ADJUSTED

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

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DCA-100SSJU —TRAILER-BRAKETROUBLESHOOTING

Table 6. Hydraulic Brake Troubleshooting

Symptom

NO BRAKES

Possible Cause

IS THE BRAKE LINE BROKEN OR KINKED?

IS THE BRAKE LINING GLAZED?

Solution

REPAIR OR REPLACE.

REBURNISH OR REPLACE

CORRECT WEIGHT.

WEAK BRAKES OR BRAKES PULL TO ONE SIDE

^{IS THE TRAILER OVERLOADED}?

IS THE BRAKE DRUMS SCORED OR GROOVED?

IS THE TIRE PRESSURE CORRECT?

MACHINE OR REPLACE.

INFLATE ALL TIRES EQUALLY

MATCH TIRES.

^{IS THE TIRES UNMATCHED ON THE SAME AXLE}?

IS THE BRAKE COMPONENTS LOOSE, BENT OR BROKEN?

IS THE BRAKE DRUMS OUT-OF-ROUND?

IS THE SYSTEM LUBRICATED?

LOCKING BRAKES

NOISY BRAKES

REPLACE COMPONENTS.

REPLACE.

LUBRICATE.

IS THE BRAKE COMPONENTS CORRECT?

REPLACE AND CORRECT

INSTALL NEW SHOES AND LININGS

DRAGGING BRAKES

IS THE BRAKE LINING THICKNESS CORRECT OR IN RIGHT WRONG

^POSITION?

^{IS THERE ENOUGH BRAKE FLUID OR CORRECT FLUID}?

REPLACE RUBBER PARTS

^{FILL WITH DOT}4 FLUID

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DCA-100SSJU — GENERATOR DECALS

The DCA -100SSJU generator is equipped with a number of safety decals. These decals are provided for operator safety

and maintenance information. The illustration below and on the preceding pages show the decals as they appear on the

machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

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

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DCA-100SSJU — GENERATOR DECALS

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DCA-100SSJU — SPECIFICATIONS

Table 7. Specifications

Generator Specifications

Model

Type

DCA-100SSJU

Revolving field, self ventilated, drip proof single bearing

Armature Connection

Voltage-3 phase

Voltage-single phase

Standby Output

Prime Output

Frequency

Star with Neutral/ Zig Zag

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

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

110 KVA (88 KW)

100 KVA (80 KW)

60 Hz

Speed

1800 rpm

Power Factor

0.8

Sound Level dB(A) Full

Load at 23 feet

Insulation

Class F

Engine Specifications

JOHN DEERE 6068TF150

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

6 cylinders

Model

Type

No. of Cylinders

Bore x Stroke

Rated Output

Displacement

Starting

(106 mmx 127 mm)

129 HP/1800 rpm

410 cu. in. (6724 cc)

Electric

Coolant Capacity

Lube Oil Capacity

10.3 gal. (39 liters)

4.5 gal. (17 liters)

6.6 gal(25.1L)/hr at full load

3.5 gal(13.3L)/hr at 1/2 load

5.0 gal(19.0L)/hr at 3/4 load

Fuel Consumption

2.1gal(8.0L)/hr at 1/4 load

Battery

Fuel

12V- 150 AH x1

#2 Diesel Fuel

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

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DCA-100SSJU — GENERAL INFORMATION

DCA-100SSJU FAMILIARIZATION

Generator

Open Delta Excitation System

The DCA-100SSJU 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.

The MQ Power Model DCA-100SSJU is a 80 kW generator

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 There are four leads: A, B, C and D. During light loads, the

industrial and construction machinery.

power to the AutomaticVoltage Regulator (AVR) is supplied

from the leads parallel connections of B&C. When loads

increase, the AVR switches and accepts power from leads

A&D. The output of leads A&D increase proportionally with

load. This of adding the voltages to each phase provides

better voltage response during heavy loads.

Engine Operating Panel

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

Tachometer

WaterTemperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Fuel level gauge

Engine Speed Switch

Pre-Heat Button

Emergency Stop Button

Battery Switch

Panel Light

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.

Panel Light Switch

Auto Start/Stop Controller

Engine

The DCA-100SSJU is powered by a 4 cycle, water cooled,

turbocharged JOHN DEERE 6068 TF 150 diesel engine.

This engine is designed to meet every performance

requirement for the generator. Reference Table 1, page 13

for engine specifications.

Generator Control Panel

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

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

In keeping with Multiquip's policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Pilot Lamp

The basic controls and indicators for the DCA-100SSJU

generator are addressed on the following pages.

Output Terminal Panel

Mechanical Governor System

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

The mechanical governor system control the RPM of the

engine. When the engine demands increase or decrease,

the mechanical governor system regulates the frequency

variation to ±1.5%. The electronic governor option in-

creases frequency variation to ±0.25%.

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 250 amps

Over-Current Relay

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DCA-100SSJU — MAJOR COMPONENTS

Figure 6. Major Components

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

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

Figure 7. Dimensions

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

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DCA-100SSJU — CONTROL PANEL

Figure 8. Control Panel

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DCA-100SSJU — CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-100SSJU " Control Panel " (Figure 8).

1. Main Circuit Breaker – This three-pole, 250 amp main

breaker is provided to protect the UNV voltage output

terminals from overload.

2. AC Ammeter – Indicates the amount of current the

load is drawing from the generator.

3. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the

load connected to any phase of the output terminals, or

to be switched off.

4. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage

between any two phases of the output terminals or to

be switched off.

5. Voltage Regulator Control – Allows manual

adjustment of the generator’s output voltage.

6. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz ±1 Hz .

7. AC Voltmeter – Indicates the single phase output

voltage present at the UNV terminals.

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

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

Figure 9. Engine Operating Panel

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

The definitions below describe the controls and functions of

the DCA-100SSJU " Engine Operating Panel " (Figure 9).

1. Panel light - Normally used in dark places or at night.

When activated, panel will luminate. When the generator

is not in use, turn the panel light switch to the ‘OFF’

position.

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

panel light.

3. Oil Pressure Gauge –Normal operation should be about

25 psi. When starting the generator the oil pressure

may read a bit higher, but after the engine warms up

the oil pressure should return to normal.

4. WaterTemperature Gauge – During normal operation

this gauge be should read between 165^oF to 215^oF.

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. EngineThrottle Lever-This lever will change the speed

of the engine from high to low.

9. Pre-Heat Button – Press hold this button to start the

engine in cold conditions.

10. Starter Switch with Key – This switch has three

different positions:Stop-Turn the key to stop the engine.

Start-Turn the key to this position to start the engine.

Release the key once the engine has started and it will

automatically return to the operating position.

11. Oil Pressure Indicator - This indicator lets the operator

know the oil pressure is dangerously high or low and

will shut down the engine.

12. WaterTemperature Indicator - This indicator lets the

operator know the water temperature is dangerously high

and will shut down the engine.

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

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

Figure 10. Engine Operating Panel

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

The definitions below describe the controls and functions of

the DCA-100SSJU " Engine Operating Panel " (Figure

10).

been detected the MPEC 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. If

the

1. Panel light - Normally used in dark places or at night.

When activated, panel will luminate. When the generator

is not in use, turn the panel light switch to the ‘OFF’

position.

engine does not engage (start) by the third attempt, the

engine will be shutdown by the MPEC's " Over Crank

Protection" mode. If the engine engages at a speed

(RPM's) that is not safe, the MPEC will shutdown the

engine by initializing the "Over Speed Protection" mode.

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

panel light.

Also the MPEC will shutdown the generator in the event of

low oil pressure, high coolant temperature, low coolant level,

and loss of magnetic pickup. These conditions can be

observed by monitoring the LED status indicators on the

front of the MPEC module.

3. Oil Pressure Gauge –Normal operation should be about

25 psi. When starting the generator the oil pressure

may read a bit higher, but after the engine warms up

the oil pressure should return to normal.

4. WaterTemperature Gauge – During normal operation

this gauge be should read between 165^oF to 215^oF.

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

running of the generator.If this switch is left in the "OFF"

position, the generator will not run. When this switch is

set to the manual position, the generator will start

immediately.

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.

If the generator is to be connected to a building's AC

power source via a transfer switch (isolation), place the

switch in the auto position. In this position the generator

will monitor the AC line output from the building's power

source.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s

when the rated load is applied. In addition a built in hour

meter will record the number of operational hours that

the generator has been in use.

B. Low Oil Pressure – Indicates the engine pressure

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.

8. Engine speed Handle- This handle will change the

speed of the engine from high to low.

C. High Coolant Temperature – Indicates the engine

9. Pre-Heat Button – Press hold this button

(Figure 11) until the preheat lamp is lit

(ON).

temperature has exceeded 215°F. The engine

temperature is detected using variable resistive values

from the temperature sending unit.This is considered a

major fault.

Figure 11. Preheat Button

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 preset at 3 cycles with a 10

second duration. This is considered a major fault.

10. MPEC – Microprocessor

Engine Control Module –

(MPEC) has a vertical row of

status LED's (Figure 11), that

when lit, indicate that an engine

malfunction (fault), has been

E. Overspeed Shutdown – Indicates the engine is running

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

Engine Running – Indicates that engine is running

detected. When a fault has

at a safe operating speed.

Figure 12. MPEC

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

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

OUTPUTTERMINAL FAMILIARIZATION

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

Connecting Load

Loads can be connected to the generator by the UNV Lugs or

the convenience receptacles. (See figure 15). Make sure to

read the operation manual before attempting to connect a load

to the generator.

Three 120/240V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 250V @50 amps

2 Load GFCI Circuit Breakers 120V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 250 amps

Over-Current Relay

Output Terminal Panel

The Output Control Panel (See Figure 16) is located on the

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

The UNV lugs are protected by a face plate cover that can

be secured in the close position by a pad lock. (See Figure

13).

FIGURE 15. Connecting Load

Circuit Breakers

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

main circuit breaker is provided to protect the UNV output

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

GFCI circuit breakers are provided to protect the GFCI

receptacles from overload.Three 50 amp load circuit breakers

have also been provided to protect the load side of the

generator from overload. Make sure to switch ALL circuit

breakers to the "OFF" position prior to starting the engine.

Maximum Output

FIGURE 13. Output Terminal Cover

The entire load connected to the UNV Lugs, all four slots in the

duplex receptacles, and the must not exceed 88 kW in standby

or 80 kW in prime output.

120Volt Receptacle

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

is provided on the output terminal. This receptacle can be

used anytime the generator is in operation. The receptacle

is controlled by the circuit breaker located on the control

panel.

Twist Lock DualVoltage Receptacles - To use these

receptacles, place the voltage selector switch in the single

phase 240/120 voltage position and adjust the output

voltage to 240 volts with the voltage regulator on the

Control Panel. Place the voltmeter change-over switch to

the U-W position and the ammeter change-over switch to

the U or W to read the output.

Pressing the reset button resets the receptacle after being

tripped. Pressing the "Test Button" (See Figure 14) in the

center of this receptacle will check the GFCI function. The

receptacle should be tested at least once a month.

FIGURE 14. GFCI Test Button

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

FIGURE 16. Output Terminal Panel

NOTE

Legs

and Ground are

considered Bonded Grounds.

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

Output Terminal Panel Available Voltages

Maximum Amps

A wide range of voltages are available to supply load to

many different applications. Voltages may be selected by

using the voltage selector switch and how you hookup

your hard wire connection to the generator. To obtain some

of the voltages listed, fine adjustment with the Voltage

Regulator on the control panel is necessary. See the table

below (Table 8) for a list of available voltages the generator

is able to supply.

The following table show the maximum amps the entire

generator can provide. Do not exceed the maximum amps

listed. (See Table 9 below.)

Table 9. Maximum Amps

Model:

DCA100SSJU

Maximum Amps

222.2 amps (4 wire)

111.1 amps (4 wire)

241 amps

Table 8. Available Voltages

Rated

Voltage

MODEL

DCA100SSJU

3 PHASE VOLTAGE

(SWITCHABLE)

208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT

120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT

Single Phase

120 Volt

SINGLE PHASE

(SWITCHABLE)

Single Phase

240 Volt

Voltage Selector Switch

The voltage selector switch is located above the UVWO

Hard Wire Hookup Panel. It has been provided for ease of

voltage selection.

Three Phase

240 Volt

CAUTION :

Three Phase

480 Volt

120 amps

NEVER switch Voltage Selector Switch

position while the engine is engaged.

Receptacle Use

When the UVWO terminals are providing power, the

receptacle power available decrease. Do not exceed

receptacle power available listed on Table 10.

Voltage Selector Switch Locking Button

Table 10. Receptacle Use

The voltage selector switch has a locking button to protect

the generator and generator load from being switched while

the engine is running. To lock the Voltage Selector Switch,

press in the red button located on the Voltage Selector

Switch, and use a pad lock to hold it into this position.

(See figure 17, page 37)

Receptacle

Power in Use

Power

Available

240/120V

240/480V Single Phase

Duplex

NEMA

5-20R 120V

Over Current Relay

3-Phase

or Twist

An over current relay is connected to the circuit breaker.

In an over current situation, both the circuit breaker and

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

not be reset, the reset button on the over current relay

must be pressed. The over current relay is located in the

control box.

Lock CS6369

KVA

100

57.7

56.5

55.3

54.1

52.9

95.8

91.7

87.5

83.4

1.2

2.4

3.6

4.8

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

How to read the output terminal gauges.

The gauges and knobs on the control panel DO NOT effect

the generator output in any fashion. They are there to

simply help the operator observe how much power is being

supplied produced at the UVWO legs.

When the Voltage selector switch is in the 240/120V

position (see figure 17), place the AC Voltmeter Change-

over switch to the W-U position and the AC ammeter

Change -over Switch to the U or W position to read the

output on the selected leg.

FIGURE 21. AC Ammeter

(Amp reading on U lug)

FIGURE 20. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

NOTE

When using plural single phase

voltages, make sure to balance

the load on each of the single

phase legs.

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

Position

FIGURE 18. AC Voltmeter

FIGURE 19. AC Voltmeter

Change-over switch

Guage

(Reading the W-U leg on

(Volt reading on W-U Lug)

the output terminal panel)

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

480/240V Hard Wire Hookup

240/120V HardWire Hookup

The output terminal panel, when suppling three phase 240

volts, will provide one circuit available at 241 amps with any

two wires plus the ground.(See Figure 25 below.) The voltage

selector switch must be set at the three phase 480/277V

position. (See figure 24 below.)

The output terminal panel, when suppling single phase 120

volts, will provide three legs available with 222.2 amps each

on three different circuits. (See Figure 23 below.) The voltage

selector switch must be set at the single phase 240/120V

position. (See figure 22 below.)

The output terminal panel, when suppling 3 phase 480 volts,

will provide one circuit available at 120 amps available with

all three wires plus ground. (See Figure 25 below.) The

voltage selector switch must be set at the three phase 480/

277V position. (See figure 24 below.)

The output terminal panel, when suppling single phase 240

volts, will provide one leg only with 111.1 amps available.

(See Figure 23 below.) The voltage selector switch must be

set at the single phase 240/120V position. (See figure 22

below.)

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

Position

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

Position

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

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

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

Voltage Selector Switch- 3 Phase 480/277V Position

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

The following are additional voltages available when the

voltage selector switch is in the 3 phase 480/277V

position. (See figure 26 below.)

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 26),

can offer SINGLE PHASE power at 480V, 440V, or 416V.

After hooking up the hard wires to the lugs as shown in

figure 29 below, 480V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 440 volt will be

reached when the Voltage Regulator Knob is turned down,

and 416 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 27).

FIGURE 27. Voltage

Selector Switch 270/120V

Single Phase

Position

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

Position

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

or 416V

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

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

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 26),

can offer SINGLE PHASE power at 277V, 254V, or 240V.

After hooking up the hard wires to the lugs as shown in

figure 30 below, 277V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 254 volt will be

reached when the Voltage Regulator Knob is turned down,

and 240 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 27).

The following connection, with the voltage selector switch

locked into the 3 phase 480/277V position (See Figure 26),

can offer THREE PHASE power at 480V, 440V, or 416V.

After hooking up the hard wires to the lugs as shown in

figure 28 below, 480V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 440 volt will be

reached when the Voltage Regulator Knob is turned down,

and 416 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 27).

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

or 416V

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

or 240V

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

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

Voltage Selector Switch- 3 Phase 240/139V Position

The following are additional voltages available when the

voltage selector switch is in the 3 phase 240/139V

position. (See Figure 31 below.)

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 31),

can offer SINGLE PHASE power at 240V, 220V, or 208V.

After hooking up the hard wires to the lugs as shown in

figure 34 below, 240V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 220 volt will be

reached when the Voltage Regulator Knob is turned down,

and 208 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 32).

FIGURE 32. Voltage

Regulator Knob located

on the control panel

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

or 208V

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

Position

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

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

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 31),

can offer SINGLE PHASE power at 139V, 127V, or 120V.

After hooking up the hard wires to the lugs as shown in

figure 35 below, 139V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 127 volt will be

reached when the Voltage Regulator Knob is turned down,

and 120 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 32).

The following connection, with the voltage selector switch

locked into the 3 phase 240/139V position (See Figure 31),

can offer THREE PHASE power at 270V, 220V, or 208V.

After hooking up the hard wires to the lugs as shown in

figure 33 below, 240V will be the voltage with the Voltage

Regulator Knob turned toward maximum. 220 volt will be

reached when the Voltage Regulator Knob is turned down,

and 208 volt when the Voltage Regulator Knob is toward

the lowest setting (See Figure 32).

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

or 208V

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

or 120V

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DCA-100SSJU — OUTPUTTERMINAL PANEL OVERVIEW

Single Phase: 120 Volt

Voltage Selector Switch- Single Phase 240/120V

Position

The following are additional voltages available when the

voltage selector switch is in the single phase 240/120V

position. (See Figure 36 below)

The following connection, with the voltage selector switch

locked into the single phase 240/120V position (See

Figure 36), will offer SINGLE PHASE power at 120V. After

hooking up the hard wires to the lugs as shown in figure 39

below, use the Voltage Regulator Knob to fine tune to

120V. (See Figure 37).

FIGURE 37. Voltage

Regulator Knob located

on the control panel

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

Position

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

Single Phase, 240 Volt

The following connection, with the voltage selector switch

locked into the single phase 240/120V position (See

Figure 36), will offer SINGLE PHASE power at 240V. After

hooking up the hard wires to the lugs as shown in figure 38

below, use the Voltage Regulator Knob to fine tune to

240V. (See Figure 37)

FIGURE 38. Hard Wire Hookup for Single Phase 240 volt

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DCA-100SSJU — INSTALLATION

Outdoor Installation

CAUTION

Install the generator in a location where it will not be exposed

to rain or sunshine. Make sure the generator is on secure

level ground so it cannot slide or shift around. Also install

the generator so the exhaust will not be discharged in the

direction of nearby homes.

An electric shock may happen when

vibrators are used. Pay close attention to

handling when operating vibrators and

always use rubber boots and gloves to

insulate the body from electrical shock.

Generator Grounding

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.

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.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to the

engine and alternator parts.

CAUTION :

Pay close attention to ventilation when

operating the generator inside tunnels and

caves. The engine exhaust contains

noxious elements. Engine exhaust must

be routed to a ventilated area.

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.

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.

2. When grounding the generator (Figure 14) connect the

ground cable between the lock washer and the nut on

the generator and tighten the nut fully.Connect the other

end of the ground cable to earth ground.

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

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

NOTE

When connecting the generator to any buildings

electrical system ALWAYS consult with a licensed

electrician.

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DCA-100SSJU — INSTALLATION

Figure 40. Typical Generator Grounding Application

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DCA-100SSJU — PRE-SETUP

General Inspection Prior to Operation

Circuit Breakers

The DCA-100SSJU generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 250 amp,

and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UNV output

be sure to check for damaged parts or components, or loose terminals from overload. In addition two single-pole, 20 amp

nuts and bolts, which could have occurred in transit.

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 load side of the

generator from overload. Make sure to switch ALL circuit

breakers to the "OFF" position prior to starting the engine.

Extension Cable

When electric power is to be provided to various tools or

loads at some distance from the generator, extension

cords are normally used. Cables should be sized to allow

for distance in length and amperage so that the voltage

drop between the generator and point of use (load) is held

to a minimum. Use the Cable Selection Guide (Table 11 )

as a guide for selecting proper cable size.

NOTE

ALWAYS consult with a licensed

electrician for correct extension

cord wire size.

Table 11. Cable Selection (60 Hz, Single Phase Operation)

Load In Watts

Maximum Allowable Cable Length

Current in

Amperes

At 120

Volts

At 240

Volts

#10 Wire

#12 Wire

#14 Wire

#16 Wire

2.5

300

600

1000 ft.

500 ft.

350 ft.

250 ft.

150 ft.

125 ft.

600 ft.

300 ft.

200 ft.

150 ft.

100 ft.

75 ft.

375 ft.

200 ft.

125 ft.

100 ft.

65 ft.

250 ft.

125 ft.

100 ft.

1200

1800

2400

3600

4800

7.5

900

1200

1800

2400

50 ft.

CAUTION: Equipment damage can result from low voltage.

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DCA-100SSJU — PRE-SETUP

Lubrication Oil

Fuel

Fill the fuel tank with clean and fresh diesel fuel. DO NOT

fill the tank beyond capacity.

Fill the engine crankcase with lubricating oil through the filler

hole, but do not overfill. Make sure the generator is level.

With the dipstick inserted all the way, but without being screw

into the filler hole, verify that the oil level is maintained

between the two notches (Figure 41) on the dipstick. See

Table 10 for proper selection of engine oil.

Pay attention to the fuel tank capacity when replenishing

fuel. Refer to the fuel tank capacity listed on page 23,

Specification Table 7.

The fuel tank cap must be closed tightly after filling. Handle

fuel in a safety container. If the container does not have a

spout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION

Never fill the fuel tank while the engine is

running or in the dark. Diesel spillage on a

hot engine can cause a fire or explosion.

If diesel spillage occurs, wipe up the spilled

diesel completely to prevent fire hazards.

Coolant

Use only drinkable tap water. If hard water or water with

many impurities is used, the inside of the engine and radiator

may become coated with deposits and cooling efficiency

will be reduced.

Figure 41. Engine Oil Dipstick

An anticorrosion additive added to the water will help prevent

deposits and corrosion in the cooling system. See the engine

manual for further details.

When checking the engine oil, be sure to check if the oil is

clean and viscous. If the oil is not clean, drain the oil by

removing the oil drain plug, and refill with the specified amount

of oil as outlined in the John Deere Engine Owner's

Manual.

Table 12. Recommended Motor Oil

Temperature Range

Type Oil

104° F ~ 23° F

(40° C ~ -5°C)

SAE 15W-40

23° F ~ 5° F

(-5° C ~ -15°C)

SAE 5W-30

Below 5° C (-15°)

SAE 30 OR SAE 0W-30

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DCA-100SSJU — PRE-SETUP

Cleaning the Radiator

CAUTION :

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

battery disconnected.

When adding coolant or antifreeze to the

radiator, do not remove the radiator cap

until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve tank.

When adding coolant to the radiator, DO NOT remove the

radiator cap until the unit has completely cooled. See Table

13 for engine, radiator, and reserve tank coolant capacities.

Make sure the coolant level in the reserve tank is always

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

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the John Deere Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect the fan belt for

damage and wear and adjust it in accordance with the John

Deere Engine Owner's Manual.

Table 13. Coolant Capacity

The fan belt tension is proper if the fan belt bends 7 to 10

mm (Figure 42) when depressed with the thumb as shown

below.

Engine and Radiator

Reserve Tank

10.3 Gal. (39 Liters)

2 Quarts (1.9 Liters)

Operation in Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 14) has been added.

Figure 42. Fan Belt Tension

CAUTION

Table 14. Anti-Freeze Operating Temperatures

Never place hands near the belts or fan while

the generator set is running.

Freezing Point

Boiling Point

Vol %

Anti-Freeze

°C

-24

-37

°F

°C

°F

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 is not

properly maintained. Add only distilled water when

replenishment is necessary.

-12

-34

106

108

222

226

The battery is sufficiently charged if the specific gravity of

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

NOTE

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

discharged and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor

contact may result in poor starting or malfunctions. Always

keep the terminals firmly tightened. Coating the terminals

with a thin film of grease will help inhibit corrosion.

When the antifreeze is mixed with

water, the antifreeze mixing ratio must

be less than 50%.

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DCA-100SSJU — PRE-SETUP

Battery Cable Installation

CAUTION

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

connected to the battery terminals as shown below. The

RED cable is connected to the positive terminal of the battery,

and the BLACK cable is connected to the negative terminal

of the battery.

Inadequate battery connections may cause

poor starting of the generator, and create

other malfunctions.

Wiring

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

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

wear and tightness.Tighten all hose clamps and check hoses

for leaks.

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

immediately.

Figure 43. Battery Connections

CAUTION

If the battery cable is connected

incorrectly, electrical damage to the

generator will occur. Pay close attention

to the polarity of the battery when

connecting the battery.

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery

terminals when the Off/Manual/Auto switch is in either

the manual or auto position (ON). ALWAYS make sure

that the Off/Manual/Auto switch is in the OFF position

when connecting the battery.

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will

help prevent corrosion around the battery terminals.

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DCA-100SSJU — LOAD APPLICATION

Single Phase Load

CAUTION

Motors and motor-driven equipment draw

much greater current for starting than

during operation.

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage and

frequency requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require 130—

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

the wattage is influenced by the efficiency, power factor and

starting system of the equipment.

An inadequate size connecting cable which cannot carry

the required load can cause a voltage drop which can burn

out the appliance or tool and overheat the cable.

When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up

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

When the voltage selector switch is in single phase (240/

120V position), place the AC voltmeter change-over switch

to the U-W position and the AC ammeter change over-switch

to the U or W position to read the output.

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.

NOTE

If wattage is not given on the

equipment's name plate, approximate

wattage may be determined by

multiplying nameplate voltage by the

nameplate amperage.

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

WATTS = VOLTAGE x AMPERAGE

If wattage is not available on the equipment, approximate

wattage may be determined by multiplying the nameplate

voltage by the nameplate amperage for three-phase:

WATTS =1.732 x VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 15.

below when connecting loads.

CAUTION:

Before connecting this generator to any

building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious injury or death

may result without this transfer switch.

Table 15. Power Factor By Load

Type of Load

Power Factor

0.4 - 0.75

1.0

Single-phase induction motors

Electric heaters, Incandescent lamps

Flourescent lamps, Mercury lamps

NOTE

0.4 - 0.9

If output (kVA) is not given on the

equipment nameplate, approximate

output may be determined by

multiplying voltage by amperage by

Electric devices, Communication

equipment

1.0

Three Phase Load

When calculating the power requirements for 3-phase power

use the following equation:

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DCA-100SSJU — GENERATOR START-UP PROCEDURE

WARNING:

2. Connect the load to the UNV terminals as shown in

The engine's exhaust contains harmful

Figure 45. These terminals can be found on the output

terminal panel, (see page 35 Figure 16).To gain access

to the output terminals lift the UNV cover. Tighten

terminal nuts securely to prevent load wires from slipping

out.

emissions. ALWAYS ventilate the

exhaust when operating inside tunnels,

excavations or buildings. Direct exhaust

away from nearby personnel.

Before Starting

Engine

1. Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be

maintained between two notches on the dipstick.

2. When there is not enough lubricating oil, fill the crankcase

with high grade motor oil. Use a high quality detergent

oil classified CC or higher (See Table 3 on page 27).

3. Check the coolant level in the radiator and subtank.

Replenish with antifreeze as necessary.Always maintain

the coolant level between the FULL and LOW markings

on the coolant container.Be sure that the radiator cap is

fastened securely.

Figure 45. UNV Terminal Lugs (Load)

4. Check the fuel level on the fuel gauge. If fuel is low, fill

the fuel tank with clean fresh unleaded automotive diesel.

If diesel spillage occurs, completely wipe up the spilled

fuel immediately.

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

negative post on the battery (Figure 46).

Before Starting

Generator and Control Panel

CAUTION:

NEVER start the engine with the

main, GFCI or load circuit breakers

in the ON position.

Be sure to disconnect the

electrical load and switch the main, load and G.F.C.I.

circuit breakers (Figure 44) to the “OFF” position prior to

starting the engine.

TTER

Figure 46. Battery Connections

Figure 44. Main, GFCI and

Load Circuit Breakers

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

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

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

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

Figure 52. Engine Speed Switch (low)

Figure 47. Engine Enclosure Doors

5. When starting the generator in COLD weather conditions,

10. If the generator is equipped with a Microprocessor

Engine Control unit (MPEC), set engine speed

switch to ‘Low’ (Figure 53).

press and hold the engine preheat button (Figure 48) .

Figure 48. Engine Pre-Heat Button

6. Check the voltage selection switch is at the desired

voltage (Figure 49).

Figure 53. Engine Speed Switch (low)

11.

Turn the Auto-Off/Reset-Manual switch to

‘Manual’ to start the engine (Figure 54). Once the

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

Listen for any abnormal noises.

Figure 49. Voltage Selection Switch

7. If the generator is equipped with a engine throttle

lever, make sure the lever is pushed in and set to

‘IDLE’ (Figure 50).

Figure 54. Auto-Off/Reset-Manual Switch

Figure 50. Engine Throttle Lever (IDLE)

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

properly, set the engine speed switch to ‘High’

(Figure 55).

8. If the generator has a starter switch, turn the key to

‘START’ (Figure 51) until the engine starts. Then

release the key to set it at ‘OPERATION’ function.

Figure 51. Engine Speed Switch (low)

Figure 55. Engine Speed Switch (high)

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

13. The generator's frequency meter (Figure 56) displays 16. The engine oil pressure gauge (Figure 60) will indicate

the 60 cycle output frequency in HERTZ.

the oil pressure (kg/ cm²) of the engine. Under normal

operating conditions the oil pressure is approximately

25 psi.

Figure 56. Frequency Meter (Hz)

Figure 60. Oil Pressure Gauge

17. The coolant temperature gauge (Figure 61) will indicate

the coolant temperature. Under normal operating

conditions the coolant temperature is between 165 and

215 degrees Fahrenheit.

14. The generator's voltage meter (Figure 57) displays the

120 VAC in VOLTS. If the voltage is not within the

specified frequency tolerance, use the voltage

adjustment control knob (Figure 58) to increase or

decrease the desired voltage.

WATER TEMP

Figure 61. Coolant Temperature Gauge

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

the engine when the generator is operating. Under normal

operating conditions this speed is approximately 1800

RPM’s.

Figure 57. Engine Speed Switch (low)

Figure 58. Voltage Adjust Control Knob

Figure 62. Engine Tachometer

15. The ammeter (Figure 59) will indicate zero amps with no

load applied. When a load is applied, this meter will

indicate the amount of current that the load is drawing

from the generator’s alternator.

19. Turn the MAIN, GFCI and LOAD circuit breakers to

their ON position (Figure 63).

Figure 63. Main and GFCI Circuit Breakers

Figure 59. Ammeter (No Load)

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

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Table of Contents

DCA-100SSJU — GENERATOR START-UP PROCEDURE (AUTO)

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

CAUTION:

it reads the anticipated amount of current with respect

to the load. The ammeter will only display a current

reading if the load is in use.

Before connecting this generator to any

building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious injury or death

may result without this transfer switch.

CAUTION:

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.

Figure 64. Ammeter (Load)

21. The generator will run until manually stopped or an

abnormal condition occurs.

Starting the generator in the "AUTO" mode is similar to

starting the generator in the "MANUAL" mode, with a few

exceptions.

CAUTION:

When running the generator in the AUTO

mode, remember the generator can start

up at any time without warning. NEVER

attempt to perform any maintenance when

the generator is in the auto mode.

When starting generator in Auto mode use the "Manual Start-

up" procedure except where noted (see below).

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

50) as outlined in the manual starting procedure.

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

AUTO position (up).

Figure 65. Off/Manual Auto Switch (AUTO)

3. Continue to follow the steps outline in the manual start-

up procedure (start at step 13, page 51).

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

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DCA-100SSJU — GENERATOR SHUTDOWN PROCEDURE

ENGINE SHUTDOWN

6. If the engine is equipped with the engine throttle lever,

To shutdown the generator, use the following procedure:

turn the key to ‘’STOP’ position (Figure 70).

1. Switch both the MAIN, GFCI and LOAD circuit breakers

(Figure 66) to the “OFF” position.

Figure 70. Engine Starter Switch (STOP)

7. Remove the load from the UNV terminal strip.

Figure 66. Main, GFCI and Load

circuit breakers

Set the engine speed switch (Figure 67) to the idle

(low) position.

Figure 67. Engine Speed Switch

3. If the engine is equipped with the engine throttle lever,

turn and push to ‘IDLE’ position (Figure 68).

Figure 68. Engine Throttle Lever (IDLE)

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

load applied.

5. Turn the Auto-Off/Reset-Manual switch from the MPEC

to “OFF/Reset” position (Figure 69).

Figure 69. Off/Manual Auto Switch

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

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Table of Contents

DCA-100SSJU — MAINTENANCE

General Inspection

Cleaning the Fuel Strainer

Prior to each use, the generating set should be cleaned and Clean the fuel strainer if it contains dust or water. Remove

inspected for deficiencies. Check for loose, missing or dust or water in the strainer cap and wash it in diesel. Securely

damaged nuts, bolts or other fasteners. Also check for fuel fasten the fuel strainer cap so that fuel will not leak. Check

or oil leaks.

the fuel strainer every 200 hours of operation or once a month.

Engine Side, Fuel, Oil and Coolant (Refer to the Engine Check Oil Level

Instruction Manual)

Check the crankcase oil level prior to each use, or when the

Air Cleaner

fuel tank is filled. Insufficient oil may cause severe damage

to the engine. Make sure the generator is level.The oil level

must be between the two notches on the dipstick as shown

in page 27, Figure 9.

Every 50 hours: Remove air cleaner element and clean heavy

duty paper element with kerosene, or foam element with

liquid detergent and hot water. Wrap foam element in a cloth

and squeeze dry. For heavy duty paper element, wipe Generator Storage

excess kerosene with towel

For storage of the generator for over 30 days, the following

is required:

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations). Always pour through the mesh filter.

Drain the fuel tank completely.

Completely drain the oil from the crankcase and refill

with fresh oil.

Removing Water from theTank

Clean all external parts of the generator with a cloth.

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

After prolonged use, water and other impurities accumulate

in the bottom of the tank. Occasionally remove the drain

cock and drain the contents. During cold weather, the greater

the empty volume inside the tank, the easier it is for water

to condense. This can be reduced by always keeping the

tank as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine,

starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system

according to the following procedure.

To restart after running out of fuel, turn the key switch to the

“START” position for 15-30 seconds. Try again, if needed.

This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions,

a clogged air cleaner will result in high fuel consumption,

loss of power and excessive carbon buildup in the

combustion chamber.

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

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Table of Contents

DCA-100SSJU — MAINTENANCE

TABLE 16

10 Hrs

DAILY

250 Hrs

500 Hrs

1000 Hrs

INSPECTION / MAINTENANCE

Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

Check for Leaks

Check for Loosening of Parts

Replace Engine Oil and Filter *¹

Clean Air Filter

ENGINE

Drain Bottom of Fuel Tank

Clean Unit, Inside and Outside

Change Fuel Filter *²

Clean Radiator and Check Coolant Protection

Level

Replace Air Filter Element

Change Corrosion Resistor

Check all Hoses and Clamps

Clean Inside of Fuel Tank

Measure Insulation Resistance Over 3M ohms

GENERATOR

Replace engine oil anf filter at 100 hours, first time only.

Replace fuel filter at 250 Hours, first time only.

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

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Table of Contents

DCA-100SSJU —TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper diagnosis based on the EngineTroubleshooting (Table 17).If

handling and maintenance inspections, but in the event of a the problem cannot be remedied, consult our company's

breakdown, use the tables shown for

business office or service plant.

TABLE 17. ENGINE TROUBLESHOOTING

SYMPTOM

POSSIBLE PROBLEM

No fuel?

SOLUTION

Replenish fuel.

Air in the fuel system?

Water in the fuel system?

Fuel pipe clogged?

Bleed system.

Remove water from fuel tank.

Clean fuel pipe.

Fuel filter clogged?

Clean or change fuel filter.

Excessively high viscosity of fuel

or engine oil at low temperature?

Use the specified fuel or engine oil.

Use the specified fuel.

Tighten nut.

Fuel with low cetane number?

Fuel leak due to loose injection

pipe retaining nut?

Engine does not start.

Incorrect injection timing?

Fuel cam shaft worn?

Adjust.

Replace.

Injection nozzle clogged?

Injection pump malfunctioning?

Clean injection nozzle.

Repair or replace.

Seizure of crankshaft, camshaft,

piston, cylinder liner or bearing?

Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and

nozzle holder.

Compression leak from cylinder?

Improper valve timing?

Piston ring and liner worn?

Excessive valve clearance?

Battery discharged?

Correct or replace timing gear.

Replace.

Adjust.

Charge battery.

Repair or replace.

Connect wiring.

Starter malfunctioning?

Key switch malfunctioning?

Wiring disconnected?

Starter does not run.

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DCA-100SSJU —TROUBLESHOOTING (ENGINE)

TABLE 18. ENGINE TROUBLESHOOTING (CONTINUED)

SYMPTOM

POSSIBLE PROBLEM

Fuel filter clogged or dirty?

Air cleaner clogged?

SOLUTION

Clean or change.

Fuel leak due to loose injection

pipe retaining nut?

Tighten nut.

Repair or replace.

Adjust.

Injection pump malfunctioning?

Engine revolution is not smooth.

Incorrect nozzle opening

pressure?

Injection nozzle stuck or

clogged?

Repair or replace.

Fuel over flow pipe clogged?

Governor malfunctioning?

Excessive engine oil?

Clean.

Repair.

Reduce to the specified level.

Piston ring and liner worn or

stuck?

Repair or replace.

Either white or blue exhaust gas

is observed.

Incorrect injection timing?

Deficient compression?

Overload?

Adjust.

Adjust top clearance.

Lessen the load.

Use the specified fuel.

Clean or change.

Repair or replace the nozzle.

Adjust.

Low grade fuel used?

Fuel filter clogged?

Either black or dark gray exhaust

gas is observed.

Air cleaner clogged?

Deficient nozzle injection?

Incorrect injection timing?

Engine's moving parts seem to

be seizing?

Repair or replace.

Deficient output.

Uneven fuel injection?

Repair or replace the injection pump.

Repair or replace the nozzle.

Deficient nozzle injection?

Replace head gasket, tighten cylinder head bolt, glow plug and

nozzle holder.

Compression leak?

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

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DCA-100SSJU —TROUBLESHOOTING (GENERATOR/ENGINE)

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

breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 19) and the

MPEC trouble shooting table (Table 20). If the problem cannot be remedied, consult our company's business office or

service plant.

TABLE 19. ENGINE & GENERATOR TROUBLESHOOTING

SYMPTOM

POSSIBLE PROBLEM

SOLUTION

Dead battery?

Replace battery.

Replace switch.

Replace fuse.

Engine fails to start and starter

does not rotated.

Defective starter switch?

Fuse F5 burned out?

Broken pre-heat circuit?

No fuel?

Check pre-heat circuit.

Add fuel.

Engine fails to start and starter

rotates.

Defective wiring?

Check wiring.

Clogged fuel strainer?

Clogged air cleaner?

Disconnected wiring?

Clean or replace.

Check and repair wiring.

Engine starts and remains at low

speed.

No voltage present in AC power

source?

Replace rectifier (RE1).

Defective rotor?

Replace rotor.

Engine speed rises and no voltage

is present in AC power source.

Defective voltmeter?

Disconnected wiring?

Replace voltmeter.

Check and repair wiring.

Layer short-circuit in armature

winding?

Replace armature.

Defective circuit breaker (protector)?

Replace circuit breaker (protector).

Repair or replace armature.

Engine speed rises and AC power

voltage is too low or cannot be

used.

Layer short-circuit, broken wires in

armature winding?

Defective engine regulator?

Defective wiring?

Replace regulator.

Engine speed rises and battery

discharges too soon.

Repair or replace wiring.

Repair or replace alternator.

Replace alternator bearings.

Defective alternator?

Engine speed rises and engine

seems overloaded.

Damaged alternator bearing?

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

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Table of Contents

DCA-100SSJU —TROUBLESHOOTING (MPEC)

TABLE 20. MPEC TROUBLESHOOTING

Sympton

Possible Cause

Solution

Low oil level?

Fill oil level.

Oil pressure sending unit failure?

Time delay malfuntion in MPEC?

Wire shorted?

Replace oil pressure sending unit.

Refer to dealer.

Low oil pressure light is

on.

Inspect/repair wire.

Fill coolant level.

Low coolant level?

Low coolant level light

is on.

Sending unit failure?

Replace sending unit.

Replace/charge battery.

Tighten/replace fan belt.

Clean/repair radiator grill.

Close doors.

Low battery voltage?

Fan belt tension incorrect?

Air flow is not circulation through radiator?

Doors open?

Exhaust leaking?

Replace/repair gaskets or faulty part.

Check/reduce load.

Replace thermostat.

Clear all air intakes.

Replace temperature switch.

Fill fuel level.

High coolant temperture

light is on.

Generator being overloaded?

Thermostat failure?

Air intake blocked?

Temperature switch failure?

No or low Fuel?

Overcrank light is on.

Overspeed light is on.

MPEC needs to be calibrated?

RPM engine speed too high?

Governor actuator needs to be adjusted?

Governor controller needs to be adjusted?

MPEC needs to be calibrated?

Magnetic pick up out of adjustment?

Magnetic pick up dirty?

Refer to dealer.

Adjust RPM.

Adjust governor actuator.

Adjust governor controller.

Refer to dealer.

Adjust magnetic pick up.

Clean magnetic pick up.

Loss of MPU light(s) or

on.

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

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Table of Contents

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts

book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial

number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the

corresponding part is utilized only with this specific model

number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, , #,

+, or %, belong to the same assembly or kit.

Note: If more than one of the same reference number is

listed, the last one listed indicates newest (or latest)

part available.

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

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Table of Contents

DCA-100SSJU — SUGGESTED SPARE PARTS

DCA-100SSJUW/JOHN DEERE 6068TF150 DIESEL ENGINE

1TO 3 UNITS

Qty.

P/N

Description

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

1 ......... 0601820671 ............ AUTOMATICVOLTAGE REGULATOR

1 ......... 0601840073 ............ RHEOSTATVOLTAGE REGULATOR

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

1 ......... M3310500003 ......... RADIATOR HOSE

1 ......... M3310500103 ......... RADIATOR HOSE

1 ......... 0193601080 ............ RADIATOR HOSE

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

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

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

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

1 ......... 0602123261 ............ UNIT WATER PRESSURE

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

3 ......... AR51481................. KEY, STARTER SWITCH

1 ......... ECU8899N.............. ENGINE CONTROLLER

S/N7400001TO 7400295

S/N7400296~

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

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

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DCA-100SSJU --- GENERATOR ASSY.

GENERATOR ASSY.

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

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Generator

Table of Contents

DCA-100SSJU --- GENERATOR ASSY.

GENERATOR ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

C0110000220 ROTOR ASSY.

FIELD ASSY

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

8101070033

8101611014

8101015003

0012110030

0042510000

8101026013

0601821349

0601822601

8001020004

8001020504

0010110020

0040010000

0601000209

0071906311

FAN

COUPLING DISK

BALANCING PLATE

HEX. HEAD BOLT

LOCK WASHER

SET PLATE, RECTIFIER

RECTIFIER .......................................... 2 ............PT 3610

SURGE ABSORBER ........................... 1 ............ERZ-M14JK21A

INSULATOR WASHER

HEX. HEAD BOLT

LOCK WASHER

BALANCING WEIGHT KIT

BEARING ............................................. 1 ............6311DDU C3

C0130000103 STRATOR ASSY

C0130200003 STRATOR ASSY.

S/N7400001 TO 7400356

S/N7400357~

0845041804

8101315202

8101350013

0012110070

0042610000

0041210000

0010110035

0040010000

0041210000

8101310014

8131312014

8131331003

0017106012

8101333003

0010106030

0040006000

0041206000

8101614003A

0013904044

034320415

GROMMET

END BRACKET

FIELD ASSY EXCITER

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

LOCK WASHER

PLAIN WASHER

HEX. HEAD BOLT

LOCK WASHER

Full View

PLAIN WASHER

COVER, BEARING

GASKET, BEARING

COVER, END BRACKET

HEX. HEAD BOLT

COVER, END BRACKET

HEX. HEAD BOLT

LOCK WASHER

PLAIN WASHER

COUPLING RING ................................ 1 ............REPLACES M2163400003

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

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

0043604000

0070506306

0012810030

0010310035

0012810030

0042510000

8111332014

0605000063

0030016000

0040016000

0600815000

LOCK WASHER

BEARING ............................................. 1 ............6303ZZ

HEX. HEAD BOLT

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

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

LOCK WASHER ................................. 12 ............S/N7400001 TO 7400160

COVER, FAN

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

HEX. NUT

LOCK WASHER

NUT

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

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DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

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Control Box

DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

M3246700404

M3213000202

M3213000212

M3213000222

M3213000232

0601808814

0021005080

0601823863

0027104015

0601820671

0027105010

0027105015

0601806118

0027106015

0601820845

0601820846

M1260600004

0027104015

0027104010

M3213500003

M3213500013

0016906015

M3923100004

M3276600004

M3213600003

0330000295

M3260500004

0021104010

0016006015

M3213600114

0016906015

0040506000

WIRE HARNESS, GENERATOR

CONTROL BOX ........................................... 1 ......... S/N7400001TO 7400033

CONTROL BOX ........................................... 1 ......... S/N7400034TO 7400150

CONTROL BOX ........................................... 1 ......... S/N7400151TO 7400295

CONTROL BOX ........................................... 1 ......... S/N7400296~

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

MACHINE SCREW

RELAY UNIT ................................................ 2 ......... MSA9013A

MACHINE SCREW

AUTOMATICVOLTAGE REGULATOR .......... 1 ......... NTA-5A-2DB

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

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

CURRENTTRANSFORMER........................ 3 ......... 814-943 200/5A

MACHINE SCREW

OVER CURRENT RELAY

FITTING BRACKET

MACHINE SCREW

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

CONTROL BOX COVER .............................. 1 ......... S/N7400001TO 7400133

CONTROL BOX COVER .............................. 1 ......... S/N7400034~

HEX. HEAD BOLT

SELECTOR SWITCH ................................... 1 ......... VY-125

SPACER

SWITCH BRACKET

EDGING

LR2D1308

LA7D1064

S/N7400001TO 7400150

Full View

SWITCH BOARD

MACHINE SCREW

HEX. HEAD BOLT

SWITCH COVER ......................................... 1 ......... REPLACES M3213600104

HEX. HEAD BOLT

TOOTHEDWASHER

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

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DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

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

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Table of Contents

Control Box

DCA-100SSJU --- CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO.

PART NO.

ITEM

CONTROL PANEL

FREQUENCY METER ................................. 1 ......... 264250 DJDJ9

AC AMMETER............................................. 1 ......... 260240LSLS1JCA

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

AC VOLTMETER.......................................... 1 ......... 260244SJSJ1

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

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

KNOB .......................................................... 1 ......... 25N

STOPPER

QTY.

REMARKS

M3223000203

0601807630

0601808953

0601801040

0601806813

0601801041

0601840073

0601840121

M1223100004

0027105015

M9220100004

0080200007

0601821370

0027104020

MACHINE SCREW

SET SCREW

SNAP RING

RECTIFIER .................................................. 1 ......... DE 4503 REPLACES 0601823240

MACHINE SCREW ...................................... 1 ......... S/N7400001TO 7400205

AND 7400296~

0027105020

0602200478

MACHINE SCREW ...................................... 1 ......... S/N7400206TO 7400295

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

S/N7400001TO 7400295

Full View

0027105040

0602202592

011808015

0601821370

MACHINE SCREW ...................................... 2 ......... S/N7400001TO 7400295

STARTER RELAY ........................................ 1 ......... AT141011

MACHINE SCREW ...................................... 2 ......... REPLACE 0027106015

RECTIFIER .................................................. 1 ......... DE 4503 REPLACES

0601823240 S/N7400296~

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

MPS6724

0027105015

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

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

LY2US12VDC

RELAY ......................................................... 1 ......... REPLACES 0601823768

S/N7400296TO 7400310

0601827656

0601823109

PYCA1

0601823223

0027104020

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

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

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

RECTIFIER .................................................. 1 ......... 30D4 S/N7400296TO 7400310

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

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

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DCA-100SSJU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

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Engine and Radiator

Table of Contents

DCA-100SSJU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

M3923200014

M3925200004

0602011491

0602041290

0602042590

0602014297

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

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

FAN BELT

1-1

1-2

1-3

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

ELEMENT, FUEL FILTER.............. 1 ...........JOHN DEERE RE92418

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

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

BLOWER FAN ............................... 1 ...........422198

0602060010

0602061000

0012110095

030210250

FAN SPACER ................................. 1 ...........JOHN DEERE R81911

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

LOCK WASHER ............................. 4 ...........REPLACES 0042510000

M2303200303

0131151240

0040012000

0605000060

0030012000

0040012000

0602011988

0602012723

0602011067

0602011066

0199101200

0602010795

0013006008

0043106000

M3310200204

M3310200404

0013006008

030206150

ENGINE FOOT

HEX. HEAD BOLT .......................... 6 ...........REPLACES 0010312030

LOCK WASHER

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

HEX. NUT

LOCK WASHER

RADIATOR ..................................... 1 ...........JOHN DEERE RE52824

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

CAP ................................................ 1 ...........S/N7400001~7400205

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

12-1

12-2

HOSE ............................................. 1 ...........S/N7400206~

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

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

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

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

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

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

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

HEX. HEAD BOLT .......................... 8 ...........REPLACES 0016908020

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

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

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

Full View

0043106000

011008020

0138102000

M3310500003

M3310500403

M3310500103

M3310500503

0605515148

0605515147

0605512190

7812014003B

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

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

HOSE BAND .................................. 2 ...........5040

HOSE BAND .................................. 2 ...........5032

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

DRAIN JOINT................................. 1 ...........REPLACES M2320300103

S/N7400001 TO 7400205

M9200200004

0150000018

011206020

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

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

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

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

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

AIR CLEANER ............................... 1 ...........FRG100297

0191300580

0605515189

0602046258

0602046377

0602040650

0603306385

0602040596

011008020

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

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

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

BAND, AIR CLEANER .................... 2 ...........P00-4076

HEX. HEAD BOLT .......................... 4 ...........REPLACES 0016908020

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

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DCA-100SSJU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

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

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Engine and Radiator

DCA-100SSJU ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

020108060

HEX. NUT ....................................... 4 ...........REPLACES 0207008000

M3373100003

0605515146

0605515200

0602022563

0602021165

0602022561

0602022562

0602022792

0602021070

0602021573

0269200406

M9300000203

0802010900

M3316100104

011008020

HOSE, AIR CLEANER

HOSE BAND .................................. 1 ...........5035

HOSE BAND .................................. 1 ...........5072

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

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

90^oELBOW .................................... 1 ...........33982-10-10+

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

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

CAP ................................................ 1 ...........10FNTX-S

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

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

RESERVE TANK

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

BRACKET, RESERVE TANK

HEX. HEAD BOLT .......................... 2 ...........REPLACES 0016908020

0193601080

M2260600014

M2260600024

0602202597

0602202592

0017105015

011808015

M3313100004

M3313100204

011008020

030206150

011008020

0602122281

0602123282

M9200100404

M9200100704

0605511395

HOSE

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

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

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

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

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

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

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

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

Full View

HEX. HEAD BOLT .......................... 4 ...........REPLACES 0016908020

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

HEX. HEAD BOLT .......................... 1 ...........REPLACES 0016908020

OIL SWITCH .................................. 1 ...........1718939011

WATER SWITCH ........................... 1 ...........1518183041

ADAPTER

ADAPTER ...................................... 1 ...........S/N7400004~

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

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

M3356200004

012210020

011206020

0207006000

0603306590

0603300285

0603306395

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

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

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

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

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

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

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

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

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

ENGINE OPERATING PANEL ASSY.

S/N 700001TO 7400295

S/N 7400296~

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

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Engine Operating Panel

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

Table of Contents

ENGINE OPERATING PANEL ASSY.

NO.

PARTS NO.

ITEM

QTY.

REMARKS

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

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

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

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

0601840190

KNOB .................................................... 1 ...........REPLACES M9320000004

S/N7400001 TO 7400295

0036003000

0605804150

0041208000

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

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

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

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

0207008000

0030008000

0605010550

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

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

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

0602180106

0030008000

0602180107

0036508000

0207006000

0041206000

0602100056

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

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

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

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

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

STARTER SWITCH .............................. 1 ...........JOHN DEERE AR58126

S/N7400001 TO 7400295

AR51481

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

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

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

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

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

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

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

TACHOMETER ..................................... 1 ...........103678

Full View

0602100028

0602100029

0601831594

0601831585

0601831584

0601831588

0602120096

0602122093

0602122271

OIL PRESSURE GAUGE ...................... 1 ...........100174

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

S/N7400001 TO 7400077

0602122272

0602123092

0602123261

0602121080

0602125090

0602103092

0601810245

0601810141

0601831330

ECU9988N

0601831340

0600500091

0601831395

0027104035

0207004000

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

WATER TEMPERATURE GAUGE........ 1 ...........100182

UNIT, WATER TEMPERATURE............ 1 ...........0202500

CHARGING AMMETER........................ 1 ...........100158

FUEL GAUGE ....................................... 1 ...........100176

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

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

PANEL LIGHT ....................................... 1 ...........9826800370

28-1

SWITCH, PANEL LIGHT ....................... 1 ...........900001

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

SWITCH ................................................ 1 ...........7562K4 S/N7400296~

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

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

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

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

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

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DCA-100SSJU --- OUTPUTTERMINAL ASSY.

OUTPUT TERMINAL ASSY.

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

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Output Terminal

DCA-100SSJU --- OUTPUTTERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO.

PART NO.

ITEM

QTY

REMARKS

M3230700003 TERMINAL PANEL

M9220100304 OUTPUT TERMINAL BOLT

0801830804

0039316000

0040016000

0041416000

0012108035

TIE BOLT........................................................ 5 ......... REPLACES M9220100404

HEX. NUT

LOCK WASHER

PLAIN WASHER

HEX. HEAD BOLT .......................................... 5 ......... REPLACES 0016908035

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

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

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

M3236100104 OUTPUT WINDOW

0605010040

0027103010

0207003000

58413

HINGE ............................................................ 2 ......... TH-TM122

MACHINE SCREW

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

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

0027103010

0207003000

011206020

0016906015

MACHINE SCREW

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

HEX. HEAD BOLT .......................................... 2 ......... REPLACES 0016906020

HEX. HEAD BOLT

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

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

Full View 17

0016906020

0601808803

0601808804

HEX. HEAD BOLT

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

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

20-1

M1260700304 BREAKER FITTING COVER

0222100150

0016906020

0601812597

CUSHION RUBBER

HEX. HEAD BOLT

RECEPTACLE................................................ 2 ......... REPLACES 0601812598;

GF530EM 125V 20A X2

0601811034

0027104015

0030004000

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

MACHINE SCREW

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

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

012212045

031112230

HEX. HEAD BOLT .......................................... 2 ......... REPLACES 0010112045

PLAIN WASHER............................................. 2 ......... REPLACES 0041212000

M9310200004 STAY RUBBER

0030012000 NUT

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

011106015

HEX. HEAD BOLT .......................................... 2 ......... REPLACES 0016906015

S/N7400001~7400295

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

0021304015

0601815194

0021304015

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

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

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

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

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DCA-100SSJU --- BATTERY ASSY.

BATTERY ASSY.

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

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Battery

DCA-100SSJU --- BATTERY ASSY.

BATTERY ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

0602220196

M9310500404 BATTERY SHEET

M9103000504 BATTERY BAND

0602220921

0040006000

M3346900004 BATTERY CABLE

M3346900104 BATTERY CABLE

CABLE

0017112025

0040512000

012210020

0040510000

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

BATTERY BOLT SET

LOCKWASHER

Full View

HEX. HEAD BOLT

TOOTHEDWASHER

HEX. HEAD BOLT...........................1........... REPLACES 0017110020

TOOTHEDWASHER

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

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DCA-100SSJU --- MUFFLER ASSY.

BATTERY ASSY.

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

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Muffler

DCA-100SSJU --- MUFFLER ASSY.

BATTERY ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

M3330100002 MUFFLER .......................................... 1 ....... S/N85000002TO 74000053

0602300167

012210025

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

HEX. HEAD BOLT.............................. 4 ....... REPLACES 0016910025

M3333000303 EXHAUST PIPE

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

Full View

M3333200004 GASKET

00017110040 HEX. HEAD BOLT

M33330400304 COVER

M33330400403 BRACKET

011008020

0602326061

HEX. HEAD BOLT.............................. 4 ....... REPLACES 0016908020

U BOLT SET ...................................... 1 ....... 89547K

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

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DCA-100SSJU --- FUELTANK ASSY.

FUEL TANK ASSY.

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

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Fuel Tank

DCA-100SSJU --- FUELTANK ASSY.

FUEL TANK ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

M3363000202 FUEL TANK

1-1

0605505070

M3363200204 TANK BAND

M9310500104 SUPPORTER SHEET

CAP, FUEL TANK

011008020

020108060

HEX. HEAD BOLT.............................. 2 ....... REPLACES 0016908020

HEX. NUT .......................................... 2 ....... REPLACES 0037908000

S/N7400001TO 74000026

0273080000

031108160

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

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

S/N7400001TO 7400026

0222100660

RUBBER SHEET

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

M9200200004 DRAIN BOLT

Full View

0150000018

011206020

0M1363400104 DRAIN HOSE

O RING .............................................. 1 ....... A P18

HEX. HEAD BOLT.............................. 2 ....... REPLACES 0016906020

0605515198

0602042420

0602042601

0191300450

0191301800

0191302200

0605515189

0605515109

0602220911

HOSE BAND ...................................... 2 ....... 5008

FUEL FILTER ..................................... 1 ....... PTG15P

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

SUCTION HOSE

RETURN HOSE

HOSE BAND ...................................... 1 ....... 91004

HOSE BAND ...................................... 5 ....... RS-8010

CLAMP............................................... 1 ....... RCT-2010

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

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DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

5 -BLACK

6 -CATERPILLARYELLOW

7 -CATO GOLD

8 -RED

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

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

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Enclosure

DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

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

M3413000212 BASE ............................................... 1 ......... S/N7400206TO 7400295

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

M1413400004 UNDER COVER

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

M3423000302 FRONT FRAME ............................... 1 ......... S/N7400001TO 7400205

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

M3493100203 ACOUSTIC SHEET ......................... 1 ......... S/N7400001TO 7400205

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

012210025

M3493100304 ACOUSTIC SHEET

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

HEX. HEAD BOLT............................ 6 ......... REPLACES 0016910025

M3433000102 CENTER FRAME

M3493200004 ACOUSTIC SHEET

0010114040

020114110

030214350

031114260

HEX. HEAD BOLT

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

LOCKWASHER .............................. 24 ......... REPLACES 0040014000

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

M3443000202 REAR FRAME ................................. 1 ......... S/N7400001TO 7400295

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

012210025

M3443300203 REAR COVER

M3443300303 DUCT, REAR COVER

HEX. HEAD BOLT............................ 4 ......... REPLACES 0016910025

Full View

M3493300303 ACOUSTIC SHEET

0207006000

011008020

HEX. NUT

HEX. HEAD BOLT...........................10 ......... REPLACES 0016908020

M3443200103 REAR DOOR.................................... 1 ......... S/N7400001TO 7400099

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

M3443600104 WINDOW PLATE

020106050

952404470

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

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

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

0027106016

MACHINE SCREW .......................... 4 ......... REPLACES 0021806015

020106050

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

M9110100204 HINGE

M9116100004 WASHER

011008020

HEX. HEAD BOLT............................ 3 ......... REPLACES 0016908020

0845031504

BLIND PLUG .................................... 2 ......... REPLACES M9310000004

M3463100203 ROOF PANEL

M3493500203 ACOUSTIC SHEET

M3463200102 ROOF PANEL

M3493500303 ACOUSTIC SHEET

M3463500104 OVER COVER, FRONT FRAME

011008020

1625165103

1625165204

HEX. HEAD BOLT...........................37 ......... REPLACES 0016908020

BONNET CAP.................................. 1 ......... REPLACES M9310000103

CHAIN ASSY. .................................. 1 ......... REPLACES M1483600204

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

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Table of Contents

DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

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

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Enclosure

DCA-100SSJU --- ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

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

S/N7400001TO 7400026

M3453200112 SPLASHER PANEL ......................... 1 ......... S/N7400027TO 7400205

M3453200122 SPLASHER PANEL ......................... 1 ......... S/N7400206TO 7400295

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

011208060

012210025

HEX. HEAD BOLT............................ 4 ......... REPLACES 0016908055

HEX. HEAD BOLT............................ 2 ......... REPLACES 0016910025

M3453000703 SIDE DOOR

M3493400704 ACOUSTIC SHEET

M3453000603 SIDE DOOR

M3493400804 ACOUSTIC SHEET

M3453000503 SIDE DOOR

M3493401004 ACOUSTIC SHEET

M3453000403 SIDE DOOR

M3493401104 ACOUSTIC SHEET

M3453300303 DUCT

M3493400904 ACOUSTIC SHEET

M3453300503 DUCT

M3493401404 ACOUSTIC SHEET

M3453300203 DUCT

View

M3493401204 ACOUSTIC SHEET

0207006000

HEX. NUT

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

0027106016

MACHINE SCREW .........................16 ......... REPLACES 0021806015

020106050

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

M9110100204 HINGE

M9110100304 HINGE

M9116100004 WASHER

011008020

0601850097

0027208025

0845031504

HEX. HEAD BOLT............................ 9 ......... REPLACES 0016908020

DOOR STOPPER

MACHINE SCREW

BLIND PLUG .................................... 8 ......... REPLACES M9310000004

M3453700004 DOOR BRACKET

011106015

011008020

0040508000

HEX. HEAD BOLT............................ 4 ......... REPLACES 0016906015

HEX. HEAD BOLT............................ 1 ......... REPLACES 0016908020

TOOTHEDWASHER

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER

WHEN ORDERING ANY PAINTED PANEL TO INDICATE

COLOR OF UNIT:

5 -BLACK

6 -CATERPILLARYELLOW

7 -CATO GOLD

8 -RED

1-ORANGE

2-WHITE

3 -SPECTRUM GRAY

4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 85

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DCA-100SSJU --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

PAGE 86 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

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Rubber Seal

DCA-100SSJU --- RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

0228900890

0229200810

0228901020

0228900990

0228900955

0228900470

0229201100

0229201040

0228800970

0228800590

0228800630

0228100665

0228100300

0228100370

0228100280

0228100365

0228100070

RUBBER SEAL

Full View

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 87

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DCA-100SSJU --- DECALS

DECAL ASSY.

PAGE 88 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

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Decal

DCA-100SSJU --- DECALS

DECAL ASSY.

NO.

PART NO.

ITEM

QTY.

REMARKS

M1550000204 DECAL;NOTE...................................................... 1 ......... M15000020

M1550000703 DECAL; AUXILIARY OUTPUT ............................. 1 ......... M15000070

M3550000304 DECAL;NOTE...................................................... 1 ......... M35000030

M3550000402 DECAL;GENERATOR CONTROL........................ 1 ......... M35000040

M3550000202 DECAL; ENGINE OPERATING ............................ 1 ......... M35000020 S/N7400001TO 7400295

M3550000212 DECAL; ENGINE OPERATING ............................ 1 ......... M35000021 S/N 7400296~

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

M9500100004 DECAL;WATER ................................................... 1 ......... M90010000

M8400100104 DECAL;WATER DRAIN PLUG ............................. 1 ......... M90010010 S/N7400001TO 7400205

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

M9500300104 DECAL; + ............................................................. 1 ......... M90030010

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

M9500500104 DECAL; FUEL DRAIN PLUG................................ 1 ......... M90050010

M9503000004 DECAL;WARNING ............................................... 2 ......... M90300000

M9503000103 DECAL;WATER, OIL CHECK .............................. 1 ......... M90300010

M9503100004 DECAL;WARNING ............................................... 1 ......... M90310000

M9503200004 DECAL;WARNING ............................................... 1 ......... M90320000

M9510100004 DECAL;CAUTION................................................ 1 ......... M91010000

M9510200002 DECAL; MQ ......................................................... 1 ......... M91020000

M9520000004 DECAL; GROUND ................................................ 1 ......... M92000000

M9520000104 DECAL; AMMETER CHANGE OVER SWITCH ... 1 ......... M92000010

M9520000204 DECAL;VOLTMETER CHANGE OVER SWITCH 1 ......... M92000020

M9520100004 DECAL;WARNING ............................................... 2 ......... M92010000

M9520100204 DECAL;CAUTION................................................ 1 ......... M92010020A

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

M9520100404 DECAL;DANGER ................................................ 1 ......... M92010040

M9520100503 DECAL;WARNING ............................................... 1 ......... M92010050

M9520200003 DECAL; CONNECTION OF OUTPUT CABLE ..... 1 ......... M92020000

M9520200104 DECAL; OVER CURRENT RELAY ....................... 1 ......... M92020010

Full View

M3560100003 STRIPE; WHISPERWATT

M3560100103 STRIPE; MP POWER

M3560100203 STRIPE

M3560100404 STRIPE

M3560100703 STRIPE; 100

M3560100803 STRIPE; 100

M3560100604 STRIPE

0600500090

0021106015

M3552000103 DECAL; OPERATING PROCEDURES ................. 1 ......... M35200010 S/N7400296~

MB1552000103 DECAL;CAUTION................................................ 2 ......... B1520010 S/N7400296~

C9505300004 DECAL;CAUTION................................................ 1 ......... C90530000 S/N7400296~

EMBLEM

MACHINE SCREW

9039209064

DECAL; START CONTACT................................... 1 ......... S-4468 S/N7400296~

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 89

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Table of Contents

TERMS AND CONDITIONS OF SALE — PARTS

Effective: July 1, 2000

PAYMENT TERMS

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

partsmustbereturnedfreightprepaidto

Multiquip’sdesignatedreceivingpoint.

Terms of payment for parts are net 10 days.

Prices are subject to change without prior

notice.Pricechangesareeffectiveonaspecific

5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate

condition,intheoriginalMultiquippackage willbebilledattherevisedprice.Rebatesfor

(ifany),andwithMuiltiquippartnumbers price declines and added charges for price

FREIGHTPOLICY

All parts orders will be shipped collect or

prepaidwiththechargesaddedtotheinvoice.

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

Multiquip’s responsibility ceases when a

signedmanifesthasbeenobtainedfromthe

carrier,andanyclaimforshortageordamage

mustbesettledbetweentheconsigneeandthe

carrier.

clearly marked.

increaseswillnotbemadeforstockonhand

atthetimeofanypricechange.

6. Thefollowingitemsarenotreturnable:

Multiquipreservestherighttoquoteandsell

directtoGovernmentagencies,andtoOriginal

EquipmentManufactureraccountswhouse

our products as integral parts of their own

products.

a. Obsolete parts. (If an item is listed

in the parts price book as being

replaced by another item, it is

obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings,

andotherrubberparts)thatwere

purchasedmorethansixmonths

priortothereturndate.

MINIMUMORDER

SPECIALEXPEDITINGSERVICE

TheminimumchargeforordersfromMultiquip

is $15.00 net. Customers will be asked for

instructionsregardinghandlingofordersnot

meetingthisrequirement.

A$20.00to$50.00surchargewillbeaddedto

theinvoiceforspecialhandlingincludingbus

c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases

netpriceoflessthan$5.00.

where Multiquip must personally deliver the

partstothecarrier.

d. Special order items.

RETURNEDGOODSPOLICY

e. Electricalcomponents.

LIMITATIONSOFSELLER’SLIABILITY

Returnshipmentswillbeacceptedandcredit

will be allowed, subject to the following

provisions:

Paint,chemicals,andlubricants.

Multiquip shall not be liable here under for

damagesinexcessofthepurchasepriceofthe

item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental

damages.

g. Decalsandpaperproducts.

h. Items purchasedinkits.

1. AReturnedMaterialAuthorizationmust

beapprovedbyMultiquippriortoshipment.

7. Thesenderwillbenotifiedofanymaterial

receivedthatisnotacceptable.

2. ToobtainaReturnMaterialAuthorization,

alistmustbeprovidedtoMultiquipParts

Sales that defines item numbers,

quantities,anddescriptionsoftheitems

tobereturned.

8. Such material will be held for 5 working

days from notification, pending

instructions. If a reply is not received

within5days,thematerialwillbereturned

tothesenderathisexpense.

LIMITATIONOFWARRANTIES

a. Thepartsnumbersanddescriptions

mustmatchthecurrentpartsprice

list.

Nowarranties,expressorimplied,aremade

in connection with the sale of parts or trade

accessories nor as to any engine not

manufacturedbyMultiquip.Suchwarranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes not

authorizes any person to assume for it any

other obligation or liability whatever in

connectionwiththesaleofitsproducts.Apart

fromsuchwrittenstatementofwarranty,there

arenowarranties,express,impliedorstatutory,

which extend beyond the description of the

productsonthefacehereof.

9. Creditonreturnedpartswillbeissuedat

dealer net price at time of the original

purchase,lessa15%restockingcharge.

b. Thelistmustbetypedorcomputer

generated.

10. In cases where an item is accepted for

which the original purchase document

can not be determined, the price will be

basedonthelistpricethatwaseffective

twelvemonthspriortotheRMAdate.

c. Thelistmuststatethereason(s)for

thereturn.

d. The list must reference the sales

order(s)orinvoice(s)underwhich

theitemswereoriginallypurchased.

11. Credit issued will be applied to future

purchasesonly.

e. Thelistmustincludethenameand

phonenumberoftheperson

requestingtheRMA.

3. A copy of the Return Material

Authorizationmustaccompanythereturn

shipment.

PAGE 90 — DCA-100SSJU — PARTS AND OPERATION MANUAL (STD) — REV. #2 (05/03/01)

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NOTE PAGE

DCA-100SSJU — PARTS AND OPERATION MANUAL (STD)— REV. #2 (05/03/01) — PAGE 91

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PARTS AND OPERATION MANUAL

Table of Contents

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HANDWHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERVICE DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

MULTIQUIPINC.

18910 WILMINGTON AVE.

PARTS DEPARTMENT:

800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

800-421-1244

SERVICE DEPARTMENT:

800-835-2551

FAX:310-537-3927

FAX:310-638-8046

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

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