MULTIQUIP Power WHISPERWATT DCA-100SSJU User manual

© COPYRIGHT 2001, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
MULTIQUIPINC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX:[phone] FAX:[phone]
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:[phone] or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
MAIN
800/421-1244 or 310/537-3700
FAX: [phone]

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 :
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