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Multiquip DCA-220SSJ operation manual PROPOSITION 65WARNING, Diesel engine exhaust and some of

Models: DCA-220SSJ

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PROPOSITION 65WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)

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Multiquip DCA-220SSJ operation manual PROPOSITION 65WARNING, Diesel engine exhaust and some of

Contents

MODELS DCA-220SSJ DCA-220SSJU PARTS LIST NO. C1870300404OPERATION AND PARTS MANUAL WHISPERWATTTM SERIESPROPOSITION 65WARNING Diesel engine exhaust and some ofDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE COMPONENT DRAWINGS TABLE OF CONTENTSSpecification and part NOTEnumber are subject to change without noticeWhen ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Order parts on-line using Multiquip’s SmartEquip websiteTable 2. Engine Speciﬁcations DCA-220SSJ/SSJU - SPECIFICATIONSTable 1. Generator Speciﬁcations PhaseFigure 1. Dimensions DCA-220SSJ/SSJU - DIMENSIONS TOP, SIDE AND FRONTTABLE 3. DIMENSIONS Dimension ft. mmSAFETY MESSAGE ALERT SYMBOLS DCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS DANGERCAUTION - ACCIDENTAL STARTING DCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - OVER-SPEED CONDITIONSDANGER - READTHIS MANUAL General SafetyDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION GeneratorGenerator Grounding Electrical SafetyDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION DANGER - ELECTROCUTION HAZARDSDANGER - EXPLOSION HAZARDS Maintenance SafetyBattery Safety DCA-220SSJ/SSJU - RULES FOR SAFE OPERATIONDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION Towing &Transporting SafetyEmergencies ALWAYS know the location of the nearest fire extinguisherDCA-220SSJ/SSJU - GENERATOR DECALS Figure 2. Generator DecalsDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE DCA-220SSJ/SSJU - GENERATOR DECALSFigure 3. Generator Decals Cont inued DCA-220SSJ/SSJU - INSTALLATION Figure 4.Typical Generator Grounding ApplicationIndoor Installation DCA-220SSJ/SSJU - INSTALLATIONOutdoor Installation CAUTION - EXHAUST HAZARDEngine Operating Panel DCA-220SSJ/SSJU - GENERAL INFORMATIONGenerator Generator Control PanelOutput Terminal Panel Assembly DCA-220SSJ/SSJU - MAJOR COMPONENTSFigure 5. Major Components Output Receptacles AssemblyDisplay Parameters DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYFigure 6. Diagnostic Display Panel 1800 RPM DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYFirst Time Start Up Main Menu NavigationDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Stored Fault CodesEngine Configuration Data 1800 RPM1800 RPM DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYFirst Time Start Up Main Menu NavigationEngine Configuration Data DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYStored Fault Codes 1800 RPM1800 RPM FAULTS ANDWARNINGS Auxiliary Gage FaultDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPM1800 RPM Active Fault CodesDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1000 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Backlight AdjustmentShut Down Codes 1800 RPM1800 RPM Contrast AdjustmentDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Setup 1- Up DisplaySelect Units 1800 RPMSetup” menu DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY3. Once the “Setup 1-up Display” menu icon has been 6. Touch the “Enter Button” to activate the “Use Defaults” functionNote that the numbers DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM now indicate the new order1800 RPM Setup 4-Up DisplayDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPM Utilities information and troubleshootingDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE“Gage Data” is selected the PowerView will DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYWhen the gage data has cleared, the display version currently in the diagnostic displaySERIAL PORT SETUP MODBUS SETUPDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY MODBUS SETUPDATA ERROR DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYGLOSSARY Troubleshooting information CANBUS FAILURE TIMEOUT ECU NOT RESPONDINGDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE DCA-220SSJ/SSJU - GENERATOR CONTROL PANELFigure 7. Generator Control Panel DCA-220SSJ/SSJU - ENGINE OPERATING PANEL Figure 8. Engine Operating PanelDCA-220SSJ/SSJU - ENGINE OPERATING PANEL 14. Auto On/Off Engine Controller MPECFigure 9. Output Terminal Panel DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Familiarization Lift up on the cover to gain access to receptacles and terminalFigure 12.Voltage Regulator Control Knob DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATION100VAC GFCI Receptacles Figure 10. G.F.C.I. ReceptacleOver Current Relay Connecting LoadsFigure 15. Over Current Relay Figure 14. Connecting Loads DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONThree Phase Load Single Phase LoadTable 5. Power Factor By Load DCA-220SSJ/SSJU - LOAD APPLICATIONGenerator OutputVoltages DCA-220SSJ/SSJU - GENERATOR OUTPUTSTable 7. Voltages Available Voltage Change-Over BoardMaximum Amps How to Read the OutputTerminal GaugeDCA-220SSJ/SSJU - GENERATOR OUTPUTS/ GAUGE READING Table 10. Generator Maximum Amps1Ø-200V UVWOTerminal Output Voltages DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 3Ø-200V UVWOTerminal Output Voltages1Ø-400V UVWOTerminal Output Voltages DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-400V UVWOTerminal Output Voltages 1Ø-230V UVWOTerminal Output VoltagesLubrication Oil DCA-220SSJ/SSJU - PRE-SETUPCircuit Breakers Fuel CheckWARNING - RESPIRATORY HAZARDS DCA-220SSJ/SSJU - PRE-SETUPRefueling Procedure Figure 33. Fueling the GeneratorCoolant Antifreeze Cleaning the RadiatorAir Cleaner Table 12. Coolant CapacityFigure 37. Battery Connections BatteryBattery Cable Installation CAUTION - BATTERY SERVICING SAFETYFigure 42. MPEC Control Switch Manual Position DCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE MANUALFigure 41. Engine Speed Switch Low Before StartingFigure 46. Frequency Meter Hz Figure 44. Engine Speed Switch HighFigure 43. Active Fault Code Message Figure 47. VoltmeterNo Load Figure 48.Voltage Adjust Control KnobCAUTION - BACKUP GENERATOR USE Figure 50. OilCAUTION - ENGINE SPEED SWITCH DCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE Figure 54. Engine Speed Switch HighNormal Shutdown Procedure DCA-220SSJ/SSJU - GENERATOR SHUT-DOWN PROCEDURESCAUTION - DIAGNOSTIC SWITCH Emergency Shutdown ProcedureAir Cleaner with Dust Indicator DCA-220SSJ/SSJU - MAINTENANCE ENGINETABLE 14. INSPECTION/MAINTENANCE Service DailyAir Removal DCA-220SSJ/SSJU - MAINTENANCE ENGINECleaning the Fuel Strainer Check Oil LevelDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE DCA-220SSJ/SSJU - MAINTENANCE HEATER/CHARGERTo ensure adequate starting DCA-220SSJ/SSJU - MAINTENANCE TRAILER Trailer MaintenanceHydraulic Surge Brakes Brake AdjustmentBrakes Figure 60. Hydraulic Brake Components ActuatorTireWear/Inflation Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD SuspensionFigure 62. Wheel Lug Nuts Tightening Sequence DCA-220SSJ/SSJU - MAINTENANCE TRAILERLug Nut Torque Requirements DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEDCA-220SSJ/SSJU -TRAILERWIRING DIAGRAM Figure 63. Trailer/Towing Vehicle Wiring DiagramDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE DCA-220SSJ/SSJU - GENERATORWIRING DIAGRAMFigure 64. Generator Wiring Diagram DCA-220SSJ/SSJU - ENGINEWIRING DIAGRAM Figure 65. Engine Wiring DiagramSYMPTOM DCA-220SSJ/SSJU -TROUBLESHOOTING GENERATORTABLE 19. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMSYMPTOM DCA-220SSJ/SSJU -TROUBLESHOOTING ENGINE CONTROLLERTABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC POSSIBLE PROBLEMNOTE PAGE DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEPART NO. Column DCA-220SSJ/SSJU - EXPLANATION OF CODE IN REMARKS COLUMNNO. Column QTY. ColumnW/JOHN DEERE 6068HF485TURBO DIESEL ENGINE 1 TO 3 UNITS DCA-220SSJ/SSJU - SUGGESTED SPARE PARTSDCA-220SSJ/SSJUWHISPERWATTGENRATOR DescriptionDCA-220SSJ/SSJU - GENERATOR ASSY GENERATOR ASSYDCA-220SSJ/SSJU - GENERATOR ASSY PART NAMEREMARKS HEX. SOCKET HEAD CAP SCREWDCA-220SSJ/SSJU - GENERATOR ASSY. CONT GENERATOR ASSY. CONT DCA-220SSJ/SSJU - GENERATOR ASSY. CONTPART NAME DCA-220SSJ/SSJU- CONTROL PANEL ASSY CONTROL PANEL ASSYDCA-220SSJ/SSJU- CONTROL PANEL ASSY QTY. REMARKSCHANGE- OVER SWITCH, VOLTMETER PART NAMEDCA-220SSJ/SSJU- CONTROL BOX ASSY CONTROL BOX ASSYREMARKS DCA-220SSJ/SSJU- CONTROL BOX ASSYPART NAME DCA-220SSJ/SSJU- CONTROL BOX ASSY. CONT CONTROL BOX ASSY. CONTDCA-220SSJ/SSJU- CONTROL BOX ASSY. CONT PART NAMEDCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYREMARKS DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYPART NAME ENGINE, JOHN DEERE 6068HF485DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY PART NAME OUTER ELEMENT, AIR CLEANER ................ 1 ........... P812363DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY BRACKET, INTER COOLER PIPEDCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY REMARKS DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYPART NAME DCA-220SSJ/SSJU- OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYOUTLET CABLE COVER SUPPORTER DCA-220SSJ/SSJU- OUTPUTTERMINAL ASSYPART NAME OUTPUT TERMINAL ASSYDCA-220SSJ/SSJU- BATTERY ASSY BATTERY ASSYREMARKS DCA-220SSJ/SSJU- BATTERY ASSYPART NAME EARTH CABLEDCA-220SSJ/SSJU- MUFFLER ASSY MUFFLER ASSYDCA-220SSJ/SSJU- MUFFLER ASSY PART NAMEDCA-220SSJ/SSJU- FUELTANK ASSY FUEL TANK ASSYDCA-220SSJ/SSJU- FUELTANK ASSY PART NAMEDCA-220SSJ/SSJU- ENCLOSURE ASSY ENCLOSURE ASSYDCA-220SSJ/SSJU- ENCLOSURE ASSY PART NAMEDCA-220SSJ/SSJU- ENCLOSURE ASSY. CONT ENCLOSURE ASSY. CONTENCLOSURE ASSY. CONT DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONTPART NAME DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONT DCA-220SSJ/SSJU- ENCLOSURE ASSY. CONT PART NAMEDCA-220SSJ/SSJU- RUBBER SEALS ASSY RUBBER SEALS ASSYRUBBER SEALS ASSY DCA-220SSJ/SSJU- RUBBER SEALS ASSYPART NAME DCA-220SSJ/SSJU- NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSYM45000030 DCA-220SSJ/SSJU- NAMEPLATE AND DECALS ASSYPART NAME SPECIAL EXPEDITING SERVICE Effective February 22, 2006 TERMS AND CONDITIONS OF SALE - PARTS11. Credit issued will be applied to future purchasesonly 2. ToobtainaReturnMaterialAuthorizationNOTE PAGE DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEMQ Power HERE’S HOW TO GET HELPPLEASE HAVETHE MODEL AND SERIAL NUMBER ON-HANDWHEN CALLING Contact mqpower@multiquip.com