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Multiquip DCA-220SSJ operation manual Operation And Parts Manual, PARTS LIST NO. C1870300404

Models: DCA-220SSJ

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OPERATION AND PARTS MANUAL

WHISPERWATTTM SERIES

MODELS

DCA-220SSJ

DCA-220SSJU

50 Hz GENERATOR

PARTS LIST NO. C1870300404

Revision #1 (01/06/09)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES.

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Multiquip DCA-220SSJ operation manual Operation And Parts Manual, PARTS LIST NO. C1870300404, Whisperwatttm Series

Contents

OPERATION AND PARTS MANUAL PARTS LIST NO. C1870300404MODELS DCA-220SSJ DCA-220SSJU WHISPERWATTTM SERIESDiesel engine exhaust and some of PROPOSITION 65WARNINGDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE Specification and part TABLE OF CONTENTSCOMPONENT DRAWINGS NOTEnumber are subject to change without noticeOrdering parts has never been easier PARTS ORDERING PROCEDURESWhen ordering parts, please supply Order parts on-line using Multiquip’s SmartEquip websiteTable 1. Generator Speciﬁcations DCA-220SSJ/SSJU - SPECIFICATIONSTable 2. Engine Speciﬁcations PhaseTABLE 3. DIMENSIONS DCA-220SSJ/SSJU - DIMENSIONS TOP, SIDE AND FRONTFigure 1. Dimensions Dimension ft. mmHAZARD SYMBOLS DCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERWARNING - ROTATING PARTS DCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION General SafetyDANGER - READTHIS MANUAL GeneratorDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION Electrical SafetyGenerator Grounding DANGER - ELECTROCUTION HAZARDSBattery Safety Maintenance SafetyDANGER - EXPLOSION HAZARDS DCA-220SSJ/SSJU - RULES FOR SAFE OPERATIONEmergencies Towing &Transporting SafetyDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION ALWAYS know the location of the nearest fire extinguisherFigure 2. Generator Decals DCA-220SSJ/SSJU - GENERATOR DECALSFigure 3. Generator Decals Cont inued DCA-220SSJ/SSJU - GENERATOR DECALSDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE Figure 4.Typical Generator Grounding Application DCA-220SSJ/SSJU - INSTALLATIONOutdoor Installation DCA-220SSJ/SSJU - INSTALLATIONIndoor Installation CAUTION - EXHAUST HAZARDGenerator DCA-220SSJ/SSJU - GENERAL INFORMATIONEngine Operating Panel Generator Control PanelFigure 5. Major Components DCA-220SSJ/SSJU - MAJOR COMPONENTSOutput Terminal Panel Assembly Output Receptacles AssemblyFigure 6. Diagnostic Display Panel DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYDisplay Parameters First Time Start Up DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM Main Menu NavigationEngine Configuration Data Stored Fault CodesDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPMFirst Time Start Up DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM Main Menu NavigationStored Fault Codes DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYEngine Configuration Data 1800 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY FAULTS ANDWARNINGS Auxiliary Gage Fault1800 RPM 1800 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Active Fault Codes1800 RPM 1000 RPMShut Down Codes Backlight AdjustmentDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Contrast Adjustment1800 RPM Select Units Setup 1- Up DisplayDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPM3. Once the “Setup 1-up Display” menu icon has been DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYSetup” menu 6. Touch the “Enter Button” to activate the “Use Defaults” function1800 RPM DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYNote that the numbers now indicate the new orderDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Setup 4-Up Display1800 RPM DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Utilities information and troubleshooting1800 RPM DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEWhen the gage data has cleared, the display DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY“Gage Data” is selected the PowerView will version currently in the diagnostic displayDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY MODBUS SETUPSERIAL PORT SETUP MODBUS SETUPGLOSSARY Troubleshooting information CANBUS FAILURE DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYDATA ERROR TIMEOUT ECU NOT RESPONDINGFigure 7. Generator Control Panel DCA-220SSJ/SSJU - GENERATOR CONTROL PANELDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE Figure 8. Engine Operating Panel DCA-220SSJ/SSJU - ENGINE OPERATING PANEL14. Auto On/Off Engine Controller MPEC DCA-220SSJ/SSJU - ENGINE OPERATING PANELOutput Terminal Familiarization DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONFigure 9. Output Terminal Panel Lift up on the cover to gain access to receptacles and terminal100VAC GFCI Receptacles DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONFigure 12.Voltage Regulator Control Knob Figure 10. G.F.C.I. ReceptacleFigure 15. Over Current Relay Figure 14. Connecting Loads Connecting LoadsOver Current Relay DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONTable 5. Power Factor By Load Single Phase LoadThree Phase Load DCA-220SSJ/SSJU - LOAD APPLICATIONTable 7. Voltages Available DCA-220SSJ/SSJU - GENERATOR OUTPUTSGenerator OutputVoltages Voltage Change-Over BoardDCA-220SSJ/SSJU - GENERATOR OUTPUTS/ GAUGE READING How to Read the OutputTerminal GaugeMaximum Amps Table 10. Generator Maximum AmpsUVWO Terminal Output Voltages DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONS1Ø-200V UVWOTerminal Output Voltages 3Ø-200V UVWOTerminal Output Voltages3Ø-400V UVWOTerminal Output Voltages DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONS1Ø-400V UVWOTerminal Output Voltages 1Ø-230V UVWOTerminal Output VoltagesCircuit Breakers DCA-220SSJ/SSJU - PRE-SETUPLubrication Oil Fuel CheckRefueling Procedure DCA-220SSJ/SSJU - PRE-SETUPWARNING - RESPIRATORY HAZARDS Figure 33. Fueling the GeneratorAir Cleaner Cleaning the RadiatorCoolant Antifreeze Table 12. Coolant CapacityBattery Cable Installation BatteryFigure 37. Battery Connections CAUTION - BATTERY SERVICING SAFETYFigure 41. Engine Speed Switch Low DCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE MANUALFigure 42. MPEC Control Switch Manual Position Before StartingFigure 43. Active Fault Code Message Figure 44. Engine Speed Switch HighFigure 46. Frequency Meter Hz Figure 47. VoltmeterCAUTION - BACKUP GENERATOR USE Figure 48.Voltage Adjust Control KnobNo Load Figure 50. OilWARNING - AUTO MODE MAINTENANCE DCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE AUTO MODECAUTION - ENGINE SPEED SWITCH Figure 54. Engine Speed Switch HighCAUTION - DIAGNOSTIC SWITCH DCA-220SSJ/SSJU - GENERATOR SHUT-DOWN PROCEDURESNormal Shutdown Procedure Emergency Shutdown ProcedureTABLE 14. INSPECTION/MAINTENANCE DCA-220SSJ/SSJU - MAINTENANCE ENGINEAir Cleaner with Dust Indicator Service DailyCleaning the Fuel Strainer DCA-220SSJ/SSJU - MAINTENANCE ENGINEAir Removal Check Oil LevelTo ensure adequate starting DCA-220SSJ/SSJU - MAINTENANCE HEATER/CHARGERDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE Trailer Maintenance DCA-220SSJ/SSJU - MAINTENANCE TRAILERBrakes Brake AdjustmentHydraulic Surge Brakes Figure 60. Hydraulic Brake Components ActuatorCAUTION - EYESIGHT HAZARD Tires/Wheels/Lug NutsTireWear/Inflation SuspensionLug Nut Torque Requirements DCA-220SSJ/SSJU - MAINTENANCE TRAILERFigure 62. Wheel Lug Nuts Tightening Sequence DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEFigure 63. Trailer/Towing Vehicle Wiring Diagram DCA-220SSJ/SSJU -TRAILERWIRING DIAGRAMFigure 64. Generator Wiring Diagram DCA-220SSJ/SSJU - GENERATORWIRING DIAGRAMDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE Figure 65. Engine Wiring Diagram DCA-220SSJ/SSJU - ENGINEWIRING DIAGRAMTABLE 19. GENERATOR TROUBLESHOOTING DCA-220SSJ/SSJU -TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMTABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-220SSJ/SSJU -TROUBLESHOOTING ENGINE CONTROLLERSYMPTOM POSSIBLE PROBLEMDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE NOTE PAGENO. Column DCA-220SSJ/SSJU - EXPLANATION OF CODE IN REMARKS COLUMNPART NO. Column QTY. ColumnDCA-220SSJ/SSJUWHISPERWATTGENRATOR DCA-220SSJ/SSJU - SUGGESTED SPARE PARTSW/JOHN DEERE 6068HF485TURBO DIESEL ENGINE 1 TO 3 UNITS DescriptionGENERATOR ASSY DCA-220SSJ/SSJU - GENERATOR ASSYREMARKS PART NAMEDCA-220SSJ/SSJU - GENERATOR ASSY HEX. SOCKET HEAD CAP SCREWDCA-220SSJ/SSJU - GENERATOR ASSY. CONT PART NAME DCA-220SSJ/SSJU - GENERATOR ASSY. CONTGENERATOR ASSY. CONT CONTROL PANEL ASSY DCA-220SSJ/SSJU- CONTROL PANEL ASSYCHANGE- OVER SWITCH, VOLTMETER QTY. REMARKSDCA-220SSJ/SSJU- CONTROL PANEL ASSY PART NAMECONTROL BOX ASSY DCA-220SSJ/SSJU- CONTROL BOX ASSYPART NAME DCA-220SSJ/SSJU- CONTROL BOX ASSYREMARKS CONTROL BOX ASSY. CONT DCA-220SSJ/SSJU- CONTROL BOX ASSY. CONTPART NAME DCA-220SSJ/SSJU- CONTROL BOX ASSY. CONTENGINE AND RADIATOR ASSY DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYPART NAME DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYREMARKS ENGINE, JOHN DEERE 6068HF485DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY OUTER ELEMENT, AIR CLEANER ................ 1 ........... P812363PART NAME BRACKET, INTER COOLER PIPEDCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY PART NAME DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYREMARKS OUTPUT TERMINAL ASSY DCA-220SSJ/SSJU- OUTPUTTERMINAL ASSYPART NAME DCA-220SSJ/SSJU- OUTPUTTERMINAL ASSYOUTLET CABLE COVER SUPPORTER OUTPUT TERMINAL ASSYBATTERY ASSY DCA-220SSJ/SSJU- BATTERY ASSYPART NAME DCA-220SSJ/SSJU- BATTERY ASSYREMARKS EARTH CABLEMUFFLER ASSY DCA-220SSJ/SSJU- MUFFLER ASSYPART NAME DCA-220SSJ/SSJU- MUFFLER ASSYFUEL TANK ASSY DCA-220SSJ/SSJU- FUELTANK ASSYPART NAME DCA-220SSJ/SSJU- FUELTANK ASSYENCLOSURE ASSY DCA-220SSJ/SSJU- ENCLOSURE ASSYPART NAME DCA-220SSJ/SSJU- ENCLOSURE ASSYENCLOSURE ASSY. CONT DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONTPART NAME DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONTENCLOSURE ASSY. CONT DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONT PART NAME DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONTRUBBER SEALS ASSY DCA-220SSJ/SSJU- RUBBER SEALS ASSYPART NAME DCA-220SSJ/SSJU- RUBBER SEALS ASSYRUBBER SEALS ASSY NAMEPLATE AND DECALS ASSY DCA-220SSJ/SSJU- NAMEPLATE AND DECALS ASSYPART NAME DCA-220SSJ/SSJU- NAMEPLATE AND DECALS ASSYM45000030 11. Credit issued will be applied to future purchasesonly Effective February 22, 2006 TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE 2. ToobtainaReturnMaterialAuthorizationDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE NOTE PAGEPLEASE HAVETHE MODEL AND SERIAL NUMBER ON-HANDWHEN CALLING HERE’S HOW TO GET HELPMQ Power Contact mqpower@multiquip.com