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Multiquip operation manual DCA-220SSJ/SSJU- CONTROL BOX ASSY. CONT, Control Box Assy. Cont

Models: DCA-220SSJ

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DCA-220SSJ/SSJU— CONTROL BOX ASSY. (CONT)

DCA-220SSJ/SSJU— CONTROL BOX ASSY. (CONT)

CONTROL BOX ASSY. (CONT.)

PAGE 80 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)

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Multiquip operation manual DCA-220SSJ/SSJU- CONTROL BOX ASSY. CONT, Control Box Assy. Cont

Contents

PARTS LIST NO. C1870300404 OPERATION AND PARTS MANUALMODELS DCA-220SSJ DCA-220SSJU WHISPERWATTTM SERIESPROPOSITION 65WARNING Diesel engine exhaust and some ofDCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGE TABLE OF CONTENTS Specification and partCOMPONENT DRAWINGS NOTEnumber are subject to change without noticePARTS ORDERING PROCEDURES Ordering parts has never been easierWhen ordering parts, please supply Order parts on-line using Multiquip’s SmartEquip websiteDCA-220SSJ/SSJU - SPECIFICATIONS Table 1. Generator SpeciﬁcationsTable 2. Engine Speciﬁcations PhaseDCA-220SSJ/SSJU - DIMENSIONS TOP, SIDE AND FRONT TABLE 3. DIMENSIONSFigure 1. Dimensions Dimension ft. mmDCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERDCA-220SSJ/SSJU - SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSGeneral Safety DCA-220SSJ/SSJU - RULES FOR SAFE OPERATIONDANGER - READTHIS MANUAL GeneratorElectrical Safety DCA-220SSJ/SSJU - RULES FOR SAFE OPERATIONGenerator Grounding DANGER - ELECTROCUTION HAZARDSMaintenance Safety Battery SafetyDANGER - EXPLOSION HAZARDS DCA-220SSJ/SSJU - RULES FOR SAFE OPERATIONTowing &Transporting Safety EmergenciesDCA-220SSJ/SSJU - RULES FOR SAFE OPERATION 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 ApplicationDCA-220SSJ/SSJU - INSTALLATION Outdoor InstallationIndoor Installation CAUTION - EXHAUST HAZARDDCA-220SSJ/SSJU - GENERAL INFORMATION GeneratorEngine Operating Panel Generator Control PanelDCA-220SSJ/SSJU - MAJOR COMPONENTS Figure 5. Major ComponentsOutput Terminal Panel Assembly Output Receptacles AssemblyDisplay Parameters DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYFigure 6. Diagnostic Display Panel DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY First Time Start Up1800 RPM Main Menu NavigationStored Fault Codes Engine Configuration DataDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY First Time Start Up1800 RPM Main Menu NavigationDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Stored Fault CodesEngine Configuration Data 1800 RPMFAULTS ANDWARNINGS Auxiliary Gage Fault DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM 1800 RPMActive Fault Codes DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM 1000 RPMBacklight Adjustment Shut Down CodesDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPM1800 RPM Contrast AdjustmentDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Setup 1- Up Display Select UnitsDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPMDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 3. Once the “Setup 1-up Display” menu icon has beenSetup” menu 6. Touch the “Enter Button” to activate the “Use Defaults” functionDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY 1800 RPMNote that the numbers now indicate the new order1800 RPM Setup 4-Up DisplayDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY Utilities information and troubleshooting DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY1800 RPM DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY When the gage data has cleared, the display“Gage Data” is selected the PowerView will version currently in the diagnostic displayMODBUS SETUP DCA-220SSJ/SSJU - DIAGNOSTIC DISPLAYSERIAL PORT SETUP MODBUS SETUPDCA-220SSJ/SSJU - DIAGNOSTIC DISPLAY GLOSSARY Troubleshooting information CANBUS FAILUREDATA ERROR 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 MPECDCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal FamiliarizationFigure 9. Output Terminal Panel Lift up on the cover to gain access to receptacles and terminalDCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATION 100VAC GFCI ReceptaclesFigure 12.Voltage Regulator Control Knob Figure 10. G.F.C.I. ReceptacleConnecting Loads Figure 15. Over Current Relay Figure 14. Connecting LoadsOver Current Relay DCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL FAMILIARIZATIONSingle Phase Load Table 5. Power Factor By LoadThree Phase Load DCA-220SSJ/SSJU - LOAD APPLICATIONDCA-220SSJ/SSJU - GENERATOR OUTPUTS Table 7. Voltages AvailableGenerator OutputVoltages Voltage Change-Over BoardHow to Read the OutputTerminal Gauge DCA-220SSJ/SSJU - GENERATOR OUTPUTS/ GAUGE READINGMaximum Amps Table 10. Generator Maximum AmpsDCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages1Ø-200V UVWOTerminal Output Voltages 3Ø-200V UVWOTerminal Output VoltagesDCA-220SSJ/SSJU - OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-400V UVWOTerminal Output Voltages1Ø-400V UVWOTerminal Output Voltages 1Ø-230V UVWOTerminal Output VoltagesDCA-220SSJ/SSJU - PRE-SETUP Circuit BreakersLubrication Oil Fuel CheckDCA-220SSJ/SSJU - PRE-SETUP Refueling ProcedureWARNING - RESPIRATORY HAZARDS Figure 33. Fueling the GeneratorCleaning the Radiator Air CleanerCoolant Antifreeze Table 12. Coolant CapacityBattery Battery Cable InstallationFigure 37. Battery Connections CAUTION - BATTERY SERVICING SAFETYDCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE MANUAL Figure 41. Engine Speed Switch LowFigure 42. MPEC Control Switch Manual Position Before StartingFigure 44. Engine Speed Switch High Figure 43. Active Fault Code MessageFigure 46. Frequency Meter Hz Figure 47. VoltmeterFigure 48.Voltage Adjust Control Knob CAUTION - BACKUP GENERATOR USENo Load Figure 50. OilDCA-220SSJ/SSJU - GENERATOR START-UP PROCEDURE AUTO MODE WARNING - AUTO MODE MAINTENANCECAUTION - ENGINE SPEED SWITCH Figure 54. Engine Speed Switch HighDCA-220SSJ/SSJU - GENERATOR SHUT-DOWN PROCEDURES CAUTION - DIAGNOSTIC SWITCHNormal Shutdown Procedure Emergency Shutdown ProcedureDCA-220SSJ/SSJU - MAINTENANCE ENGINE TABLE 14. INSPECTION/MAINTENANCEAir Cleaner with Dust Indicator Service DailyDCA-220SSJ/SSJU - MAINTENANCE ENGINE Cleaning the Fuel StrainerAir Removal 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 MaintenanceBrake Adjustment BrakesHydraulic Surge Brakes Figure 60. Hydraulic Brake Components ActuatorTires/Wheels/Lug Nuts CAUTION - EYESIGHT HAZARDTireWear/Inflation SuspensionDCA-220SSJ/SSJU - MAINTENANCE TRAILER Lug Nut Torque RequirementsFigure 62. Wheel Lug Nuts Tightening Sequence 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 DiagramDCA-220SSJ/SSJU -TROUBLESHOOTING GENERATOR TABLE 19. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-220SSJ/SSJU -TROUBLESHOOTING ENGINE CONTROLLER TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPECSYMPTOM POSSIBLE PROBLEMNOTE PAGE DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEDCA-220SSJ/SSJU - EXPLANATION OF CODE IN REMARKS COLUMN NO. ColumnPART NO. Column QTY. ColumnDCA-220SSJ/SSJU - SUGGESTED SPARE PARTS DCA-220SSJ/SSJUWHISPERWATTGENRATORW/JOHN DEERE 6068HF485TURBO DIESEL ENGINE 1 TO 3 UNITS DescriptionDCA-220SSJ/SSJU - GENERATOR ASSY GENERATOR ASSYPART NAME REMARKSDCA-220SSJ/SSJU - GENERATOR ASSY 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 ASSYQTY. REMARKS CHANGE- OVER SWITCH, VOLTMETERDCA-220SSJ/SSJU- CONTROL PANEL ASSY 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 ASSYDCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY PART NAMEREMARKS ENGINE, JOHN DEERE 6068HF485DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSY OUTER ELEMENT, AIR CLEANER ................ 1 ........... P812363 DCA-220SSJ/SSJU- ENGINE AND RADIATOR ASSYPART NAME 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 ASSYDCA-220SSJ/SSJU- OUTPUTTERMINAL ASSY PART NAMEOUTLET CABLE COVER SUPPORTER OUTPUT TERMINAL ASSYDCA-220SSJ/SSJU- BATTERY ASSY BATTERY ASSYDCA-220SSJ/SSJU- BATTERY ASSY PART NAMEREMARKS 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 Effective February 22, 2006 TERMS AND CONDITIONS OF SALE - PARTS 11. Credit issued will be applied to future purchasesonlySPECIAL EXPEDITING SERVICE 2. ToobtainaReturnMaterialAuthorizationNOTE PAGE DCA-220SSJ/SSJU- OPERATION AND PARTS MANUAL - REV. #1 01/06/09 - PAGEHERE’S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBER ON-HANDWHEN CALLINGMQ Power Contact mqpower@multiquip.com