MULTIQUIP Power WHISPERWATT DCA-100SSJU Bedienungsanleitung

PARTS AND OPERATION MANUAL

MULTIQUIPINC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-835-2551

FAX:310-537-3927 FAX:310-638-8046

E-mail:[email protected] •www:multiquip.com

PARTS AND OPERATION MANUAL

MQ POWER

DCA-100SSJU

WHISPERWATTTM

GENERATOR

(Standard)

PARTS LIST NO. M3870300174

S/N UP TO 7400295-100SSJU

S/N FROM 7400296~100SSJU2

Revision #2 (05/03/01)

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

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

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

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

TABLE OF CONTENTS

NOTE

Specification and part number

are subject to change without

notice.

Here's HowTo 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

TrailerTires & Suspension .................................... 16-17

TrailerWiringDiagram ................................................ 18

TrailerTroubleshooting (Electric Brakes) .................... 19

TrailerTroubleshooting(HydraulicBrakes) ................. 20

OperationDecals.................................................. 21-22

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

MQ POWER DCA-100SSJU

AC GENERATOR

GeneralInformation ................................................... 24

MajorComponents .................................................... 25

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

ControlPanel 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

GeneratorStart-upProcedure (Manual)................ 49-51

GeneratorStart-up Procedure(Auto)......................... 52

GeneratorShutdownProcedure................................. 53

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

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

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

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

PARTS ORDERING PROCEDURES

Get special freight allowances

when you order 10 or more

line items via FAX!**

■■

■

UPS Ground Service at no charge for freight

■■

■

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

No other allowances on freight shipped by any other carrier.

**Commonnuts,boltsand washers (all items under $1.00 list price)

do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

For faxed orders only

UPS

Special

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 3%

10+ items** 5%

Now! DirectTOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

800/6-PARTS-7 • 800-672-7877

■■

■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.

Extra Fax Discount

for Domestic USA

Dealers Only

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

RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engineorgenerator.

■

The engine of this generator requires an adequate free

flow of cooling air. Never operate the generator in any

enclosed or narrow area where free flow of the air is

restricted. If the air flow

is restricted it will cause

serious damage to the

generator or engine and

may cause injury to

people. The generator

engine gives off DEADLY

carbon monoxide gas.

■

High Temperatures –Allow the engine to cool before

adding fuel or performing service and maintenance

functions.Contactwith

hot

componentscancause serious

burns.

Failure to follow instructions in this manual

may lead to serious injury or even death!

This equipment is to be operated by trained

andqualifiedpersonnelonly!Thisequipment

is for industrial use only.

Thefollowingsafetyguidelinesshouldalwaysbeusedwhen

operating the DCA-100SSJU portable generator:

GENERAL SAFETY

■

DONOToperateorservicethisequipmentbefore

readingthisentiremanual.

■

This equipment should not be operated by

persons under 18 years of age.

■

NEVER operate this equipment without proper

protectiveclothing,shatterproofglasses,steel-

toed boots and other protective devices

required by the job.

■

NEVERoperatethisequipmentwhennotfeeling

well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the

influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment.Damage

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

■

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

before starting.

CAUTION

■

Alwaysuse extreme cautionwhen

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

resultfrom fuel vapors,orif fuel isspilled

on a hot engine.

■

NEVERoperatethegeneratorinan

explosiveatmosphereornearcombustible

materials.Anexplosionorfire could result

causing severe

bodily harm or even

death.

■

Topping-off to filler port is

dangerous, as it tends to spill fuel.

Always refuel in a well-ventilated area,

away from sparks and open flames.

CAUTION:

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

RULES FOR SAFE OPERATION

CAUTION

■

Backfeed to a utility system can cause electrocution

and.or property damage. Do not connect to any

building'selectrical system exceptthrough an approved

device or after building main switch is opened.

■

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

terminalconnectionsmaycausedamagetothegenerator

and electrical shock.

CAUTION

DO NOT touch or open any of the below

mentioned components while the

generator is running. Always allow

sufficienttimefortheengineandgenerator

to cool before performing maintenance.

Radiator

1. Radiator Cap - Removing the radiator cap while the

engineishotwillresultinhigh pressurized, boiling water

to gush out of the radiator, causing severe scalding to

any persons in the general area of the generator.

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.

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.

CAUTION

■

NEVER touch output terminals during operation.This is

extremely dangerous.

Always stop the machine when

contact with the output terminals is required.

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

RULES FOR SAFE OPERATION

■

NEVER Run engine without air filter. Severe engine

damage may occur.

■

Alwaysserviceaircleaner frequently to preventcarburetor

malfunction.

■

Always disconnect the battery before performing service

onthe generator.

■

Always be sure the operator is familiar with proper safety

precaution s and operations techniques before using

generator.

■

Always store equipment properly when not in use.

Equipmentshould be stored ina clean,dry locationout of

the reach of children.

■

DO NOT leave the generator runningin the manual mode

unattended.

■

DO NOT allow unauthorized people to operate this

equipment.

■

Always read, understand, and follow procedures in

Operator’sManualbeforeattemptingtooperateequipment.

■

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.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been

properlysecuredto thehookofguardframeongenerator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient

strength.

■

When lifting the generator, always use the balanced

center-point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath

the machine while lifting.

■

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

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

generatorduring transport.

Battery

Neveroverfillthebatterywithwaterabove

the upper limit.

CAUTION

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:

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

that the battery may explode.

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

cigarettes etc. The battery contains combustible gases

and liquids. If these gases and liquids come in contact

with a flame or spark, an explosion could occur.

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

charged a buildup of combustible gas will occur.

4. Alwayskeepbatterychargingandboostercablesingood

working condition. Repair or replace all worn cables.

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

toavoidriskofadangerousconcentration ofcombustible

gases.

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.

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

contact with your eyes, rinse eyes immediately with

plentyofwater,thencontactthenearestdoctororhospital,

and seek medical attention.

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

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drainfuelwhentransportinggeneratoroverlongdistances

or bad roads.

■

Always tie-down the generator during transportation by

securing the generator.

■

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. See page 10 for basic towing procedures.

Emergencies

■

Alwaysknowthelocationofthenearest

fire extinguisher

and

firstaid kit

.Knowthelocationofthenearesttelephone.

Alsoknowthephonenumbersofthenearest

ambulance

doctor

and

fire department

RULES FOR SAFE OPERATION

Maintenance Safety

■

NEVER lubricate components or attempt service on a

runningmachine.

■

Always allow the machine a proper amount of time to

cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always

replace broken parts.

■

Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant,

fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous

waste.

■

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

ground, down a drain or into any water source.

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

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.

Thefollowinglistofsuggestions should beusedwhentowing

yourgenerator:

CAUTION :

Towing Safety Precautions

Check with your county or state safety

towingregulationsdepartmentbeforetowing

yourgenerator.

■

Make sure the hitch and coupling of the towing vehicle

areratedequal to,orgreater thanthetrailer"gross vehicle

weightrating" (GVWR).

■

ALWAYS inspectthehitchandcouplingforwear.NEVER

tow a trailer with defective hitches, couplings, chains

etc.

■

Check the tire air pressure on both towing vehicle and

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

■

ALWAYS makesurethetrailerisequippedwitha"Safety

Chain".

DCA-100SSJU —TOWING RULES FOR SAFE OPERATION

■

ALWAYS attachtrailer’ssafetychaintobumperof towing

vehicle.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

The maximum speed for highway towing is 45 MPH

unlesspostedotherwise. Recommended off-roadtowing

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

terrain.

■

Place

chocked blocks

underneath wheel to prevent

rolling, while parked.

■

Place

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

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

trailer,theninsertlockingpintolockwheelstandin place,

whileparked.

■

Avoidsudden stops andstarts. Thiscancauseskidding,

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

improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

Figure 1. Generator with Trailer

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