MULTIQUIP Power WHISPERWATT DCA-100SSVU, Operation And Parts Manual

Page 1: ...S AND OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 0 11 05 07 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 100SSVU 60 Hz GENERATOR PARTS LIST NO M3870300...

Page 2: ...PAGE 2 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07...

Page 3: ...ustrations are basedontheDCA 100SSVU WHISPERWATTACGenerator MultiquipInc reservestherighttodiscontinueorchangespecifications design or the information published in this publication at any time without...

Page 4: ...28 GaugeReading 29 OutputTerminal Panel Connections 30 31 Pre Setup 32 35 Generator Start up Procedure Manual 36 37 Generator Start up Procedure Auto Mode 38 Generator Shut Down Procedure 39 Maintenan...

Page 5: ...b parts order system or by fax qualify for the following extra discounts Ordered Standard Stock orders via orders 750 list and above Fax 3 10 Web 5 10 Special freight allowances when you order 10 or m...

Page 6: ...m p r 0 0 8 1 r o t c a F r e w o P 8 0 t h g i e W y r D g k 0 3 8 1 s b l 5 3 0 4 t h g i e W t e W g k 0 2 1 2 s b l 5 7 6 4 s n o i t a c i f i c e p S e n i g n E 2 e l b a T l e d o M E G 0 2 5...

Page 7: ...E M I D 3 E L B A T e c n e r e f e R r e t t e L m m t f n o i s n e m i D r e t t e L e c n e r e f e R m m t f n o i s n e m i D A m m 0 8 7 n i 1 7 0 3 F m m 0 5 0 3 n i 8 0 0 2 1 B m m 0 8 7 n i...

Page 8: ...r SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions Gasoline engine exhaust...

Page 9: ...ng environment Thisgenerator otherproperty or the surrounding environment could be damaged if you do not follow instructions NOTE NEVER tamper with the factory settings of the engine governor or setti...

Page 10: ...R touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator HighTemperatures Allowtheengine to cool before performing service and maintenance fu...

Page 11: ...quipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC providesguidelinesforpropergroundingandspecifies that the cable ground shall be connec...

Page 12: ...sh out of the radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the coolant drain plug while the engine is hot will result in hot coolant...

Page 13: ...s depending on type of terrain Place support blocks underneath the trailer s bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank To...

Page 14: ...s Figures 2 3 These decals are provided for operator safety and maintenance information The illustration below and on the preceding page show the decals as they appear on the machine Should any of the...

Page 15: ...DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 PAGE 15 1 DCA 100SSVU GENERATOR DECALS Figure 3 Generator Decals Cont inued...

Page 16: ...PAGE 16 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 Figure 4 Typical Generator Grounding Application DCA 100SSVU INSTALLATION...

Page 17: ...m2 or larger b Aluminum 8 AWG 8 4 mm2 or larger 2 When grounding the generator Figure 4 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect...

Page 18: ...Duringsteadystateloads thepowerfromthevoltageregulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then...

Page 19: ...S e g a t l o V 3 y l b m e s s A r e t l i F r i A 4 y l b m e s s A r o t a r e n e G 5 r e g r a h C y r e t t a B r e t a e H r e t a W t e k c a J n o i t p O y l b m e s s A 6 y l b m e s s A s...

Page 20: ...PAGE 20 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 NOTE PAGE...

Page 21: ...meter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 7 Main Circuit Breaker This three p...

Page 22: ...PAGE 22 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 Figure 7 Engine Operating Panel DCA 100SSVU ENGINE OPERATING PANEL...

Page 23: ...rator automatically via the generator s auto start contacts connected to the ATS s start contacts Please refer to your ATS installation manual for further instructions for the correct installation of...

Page 24: ...20V GFCI receptacles 20 amp Two 2 GFCI Circuit Breakers 20 amps Five 5 Output Terminal Lugs U V W O Ground OutputTerminal Panel TheOutputTerminalPanel Figure8 shownbelowislocated ontheright handside l...

Page 25: ...urrent on all three receptacles is dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Tu...

Page 26: ...a 3 pole 250A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine DCA 100SSVU OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current...

Page 27: ...attention to the required starting current capacity NOTE WATTS VOLTAGE x AMPERAGE Three Phase Load When calculating the power requirements for 3 phase power use the following equation NOTE An inadequa...

Page 28: ...the voltage regulator VR control knob located on the control panel NEVER changethepositionofthevoltageselectorswitch while the engine is running ALWAYS place circuit breaker in the open position befo...

Page 29: ...ion Figure 21 AC Ammeter Amp reading on U lug Figure 20 AC Ammeter Change Over Switch ReadingVoltage To determine the voltage between two terminal lugs set the AC Voltmeter Change Over Switch to the a...

Page 30: ...rminal Lugs 240 139VThree Phase Connections 2 Connect the load wires to the OutputTerminal Lugs as shown in Figure 23 3 Turn the voltage regulator knob Figure 24 clockwise to increase voltage output t...

Page 31: ...T Figure 27 Voltage Selector Switch 480 277V Three Phase Position 3 480 277 OutputTerminal LugVoltages 1 Place the voltage selector switch in the 3 480 277 position as shown in Figure 27 3 Turn the vo...

Page 32: ...F position prior to starting the engine Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the...

Page 33: ...Figure 34 Figure 34 Full Fuel Tank Figure 35 Fuel Expansion 3 Open cabinet doors on the right side of the generator fromgeneratorcontrolpanelposition Removefuelcap and fill tank Figure 33 Figure 33 Fu...

Page 34: ...ff and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the VOLVO Engine Owner s Manual Fan BeltTension A slack fan belt...

Page 35: ...clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close...

Page 36: ...13 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 4 The output terminal lugs are protected by a plastic cover Remove this...

Page 37: ...1 willindicatethespeedoftheengine when the generator is operating Undernormaloperatingconditions this speed is approximately 1800 RPM s 9 The coolanttemperaturegauge Figure 50 will indicate the coolan...

Page 38: ...s transfer switch DANGER ELECTRICAL SYSTEM HAZARDS When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure t...

Page 39: ...nspect entire generator for any damage or loosening of components that may have occured during operation Emergency Shutdown Procedure 1 Place the MPEC Control Switch switch Figure 57 to the OFF RESET...

Page 40: ...After changing the air element press the dust indicator button to reset the indicator E C N A N E T N I A M N O I T C E P S N I 4 1 E L B A T s r H 0 1 Y L I A D s r H 0 5 2 s r H 0 0 5 s r H 0 0 0 1...

Page 41: ...fter disassembling the fuel system bleed the system according to the following procedure See the VOLVOEngine Manual for details To restart after running out of fuel turn the switch to the ON position...

Page 42: ...NLY function when commercial power has been supplied to them Figure 58 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 When using the generato...

Page 43: ...the trailer so the brake lights and turn signals can be connected to the towing vehicle 16 Application Indicates which units can be employed on a particular trailer Trailer Maintenance This section is...

Page 44: ...urgebrakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow...

Page 45: ...d loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 Figure 60 Major Suspension Components DCA 100SSVU TRAILER MAINTENANCE DO...

Page 46: ...the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 61 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes...

Page 47: ...DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 PAGE 47 1 DCA 100SSVU TRAILERWIRING DIAGRAM Figure 62 Trailer Towing Vehicle Wiring Diagram...

Page 48: ...PAGE 48 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU GENERATORWIRING DIAGRAM Figure 63 GeneratorWiring Diagram...

Page 49: ...DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 PAGE 49 1 DCA 100SSVU ENGINEWIRINGDIAGRAM Figure 64 Engine Wiring Diagram...

Page 50: ...a t o R e v i t c e f e D e c a l p e r d n a k c e h C d l e i F r e t i c x E e v i t c e f e D 1 N C n o K J s s o r c a s m h o 3 7 1 r o f k c e h C t u p t u O e g a t l o V w o L t c e r r o c...

Page 51: ...c h g i H n o s i t h g i l t c e r r o c n i n o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r...

Page 52: ...available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly...

Page 53: ...ADIATOR UPPER 1 V20412279 HOSE RADIATOR LOWER 1 V20412329 RADIATOR CAP 1 0605505070 FUEL CAP 1 V20405794 ALTERNATOR 12 VDC 2 V978515 V BELT ALTERNATOR 2 V978750 V BELT FUEL PUMP 1 V20405779 MONITOR OI...

Page 54: ...PAGE 54 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU GENERATOR ASSY GENERATOR ASSY...

Page 55: ...1 15 0071906311 BEARING 6311DDU C3 1 2 C0130200003 STATOR ASSY 1 3 0845041804 GROMMET 2 4 8101315202 END BRACKET 1 5 8101350013 FIELD ASSY EXCITER 1 6 0012110070 HEX HEAD BOLT 4 7 0042610000 WASHER L...

Page 56: ...PAGE 56 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY...

Page 57: ...1 7 0602121080 CHARGING AMMETER 1 8 0602125090 FUEL GAUGE 1 9 0601810141 PANEL LIGHT 1 10 0601831330 SWITCH PANEL LIGHT 1 11 M3351100004 ENGINE OPERATING PANEL 1 S N 7800130 AND ABOVE 12 0017106040 H...

Page 58: ...PAGE 58 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU CONTROL BOX ASSY S N 78000001 78000129 CONTROL BOX ASSY S N 7800001 7800129...

Page 59: ...NTROL BOX COVER 1 16 0016906016 HEX HEAD BOLT 4 17 M3923100004 SELECTOR SWITCH 1 S N 7800001 7800129 17A S2BG411 KNOB HANDLE BLACK 18 M3276600004 SPACER 8 19 M3213600003 SWITCH BRACKET 1 S N 7800001 7...

Page 60: ...PAGE 60 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 CONTROL BOX ASSY CONT S N 7800001 7800129 DCA 100SSVU CONTROL BOX ASSY S N 78000001 78000129...

Page 61: ...29 43 0027104030 MACHINE SCREW 1 S N 7800001 7800002 43 0027104040 MACHINE SCREW 1 S N 7800003 7800129 44 LY2DUS12VDC RELAY 1 REPLACES P N 0601827656 44A 0601823109 RELAY BASE PTF08A E 1 4B 0601824400...

Page 62: ...PAGE 62 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU CONTROL BOX ASSY S N 78000130 AND ABOVE CONTROL BOX ASSY S N 7800130 AND ABOVE...

Page 63: ...N 7800130 AND ABOVE 17A S2BG411 KNOB HANDLE BLACK 17B M3550002304 DECAL SELECTOR SWITCH NUMBER 1 S N 7800195 AND ABOVE 17C M3550002404 DECAL SELECTOR SWITCH NUMBER 1 S N 7800195 AND ABOVE 18 M32766000...

Page 64: ...PAGE 64 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU CONTROL BOX ASSY S N 78000130 AND ABOVE CONTROL BOX ASSY CONT S N 7800130 AND ABOVE...

Page 65: ...01827656 RELAY LY 2D DC12V 1 44A PTF08A RELAY BASE 1 REPLACES P N 0601823109 44B PYCA1 RELAY CLIP 2 REPLACES P N 0601824400 45 LY2DUS12VDC RELAY 1 REPLACES P N 0601823768 45A PTF08A RELAY BASE 1 REPLA...

Page 66: ...PAGE 66 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 67: ...ION 2 8 0030012000 HEX NUT 2 9 0040012000 WASHER LOCK 2 10 M3310201104 RADIATOR BRACKET 2 11 0016908020 HEX HEAD BOLT 4 12 M3310200814 SEAL BRACKET 1 13 0283202350 SEAL RUBBER 1 14 0222900510 SEAL RUB...

Page 68: ...UTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WH...

Page 69: ...EX NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 M3236400004 CABLE OUTLET COVER 1 16 M3236300004 SUPPORTER CABLE OUTLET COVER 1 17 0016906020 HEX HEAD BOLT 6 18 0601808803 CIRCU...

Page 70: ...PAGE 70 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU ACTUATOR ASSY ACTUATOR ASSY...

Page 71: ...0014208035 HEX SOCKET HEAD CAP SCREW 1 4A 0030008000 HEX NUT 1 4B 0040008000 WASHER LOCK 1 4C 0041208000 WASHER FLAT 2 5 0014208035 HEX SOCKET HEAD CAP SCREW 1 5A 0041208000 WASHER FLAT 1 6 M335430040...

Page 72: ...PAGE 72 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU BATTERY ASSY BATTERY ASSY...

Page 73: ...2220196 BATTERY 1 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY BAND 1 4 0602220921 BATTERY BOLT SET 2 5 0040006000 SPRINGWASHER 2 6 M3346900804 BATTERY CABLE 1 7 M3346900604 BATTERY CABLE 1 8 C...

Page 74: ...PAGE 74 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU MUFFLER ASSY MUFFLER ASSY...

Page 75: ...7 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M3333000713 EXHAUST PIPE 1 S N 7800001 7800012 3 M333000733 EXHAUST PIPE 1 S N 7800013 AND ABOVE 4 0602320198 GASKET 1 5 M3333200004 GASKET 1 6 0017110040 HE...

Page 76: ...PAGE 76 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU FUELTANK ASSY FUEL TANK ASSY...

Page 77: ...N HOSE 1 12 0605515198 HOSE BAND 2 13 0602042266 WATER SEPARATOR 1 13A 0602042766 ELEMENT 1 14 0017110040 HEX HEAD BOLT 2 15 0602022567 90 DEG ELBOW 2 16 0602022980 SWIVEL 2 18 0191401250 SUCTION HOSE...

Page 78: ...SSVU ENCLOSURE ASSY ENCLOSURE ASSY THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6...

Page 79: ...RAME 1 S N 7800130 AND ABOVE 10A M3493300204 ACOUSTIC SHEET 1 11 0016910025 HEX HEAD BOLT 4 11A 0040510000 TOOTHEDWASHER 1 12 M3443300203 REAR COVER 1 13 M3443300903 DUCT REAR COVER 2 13A M3493302603...

Page 80: ...ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT THE SERIAL NUMBER MAY BE REQUIRED ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WH...

Page 81: ...ET 1 36 M3453002113 SIDE DOOR 1 36A M3493411714 ACOUSTIC SHEET 1 37 M3453302103 DUCT 1 37A M3493411314 ACOUSTIC SHEET 1 38 M3453302003 DUCT 1 39 M3453301903 DUCT 1 39A M3493411514 ACOUSTIC SHEET 1 40...

Page 82: ...PAGE 82 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU RUBBER SEALS ASSY RUBBER SEALS ASSY...

Page 83: ...01020 SEAL RUBBER 2 4 0228900990 SEAL RUBBER 4 5 0228901060 SEAL RUBBER 4 6 0228900470 SEAL RUBBER 2 7 0229201100 SEAL RUBBER 4 8 0229201040 SEAL RUBBER 1 9 0228800630 SEAL RUBBER 1 10 0228800970 SEAL...

Page 84: ...PAGE 84 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY...

Page 85: ...0040 2 7 M3550001503 DECAL OPERATING PANEL 1 M35000150 ENGINE RADIATOR GROUP 3 1 M9500000004 DECAL OIL DRAIN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9503000004 DECAL WARNING MOVI...

Page 86: ...PAGE 86 DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 DCA 100SSVU NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY...

Page 87: ...XHAUST 1 M90320000 FUELTANK GROUP 7 1 M9500500004 DECAL DIESEL FUEL 1 M90050000 7 2 M9500500104 DECAL FUEL DRAIN PLUG 1 M90050010 ENCLOSURE GROUP 8 1 M9510200002 DECAL MQ 1 M91020000 8 2 0600500090 EM...

Page 88: ...nts g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pending i...

Page 89: ...DCA 100SSVU OPERATION AND PARTS MANUAL REV 0 11 05 07 PAGE 89 1 NOTE PAGE...

Page 90: ...HERE S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBERON HANDWHENCALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower multiquip co...