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operation manual DCA-220SSVU—MUFFLER ASSY, Muffler Assy
Models:
DCA-220SSVU
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Troubleshooting
Specification
Install
Parts list
DCA-220SSVU —TRAILERWIRINGDIAGRAM
Warranty
Dimension
Maintenance
Connecting Loads
Symptom
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DCA-220SSVU—
MUFFLER ASSY.
MUFFLER ASSY.
PAGE 72 —
DCA-220SSVU—
OPERATION AND PARTS MANUAL — REV. #1 (01/20/06)
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Contents
PARTS LIST NO. M4870300024A
OPERATION AND PARTS MANUAL
MODEL DCA-220SSVU
WHISPERWATTTM SERIES
Page
HERES HOW TO GET HELP
NUMBER ON-HAND WHEN CALLING
SERVICE DEPARTMENT
WARRANTYDEPARTMENT
TABLE OF CONTENTS
Specification and part
COMPONENT DRAWINGS
NOTEnumber are subject to change without notice
PARTS ORDERING PROCEDURES
When ordering parts
please supply the following information
Here’s how to get help
DCA-220SSVU— SPECIFICATIONS
Table 1. Generator Specifications
Table 2. Engine Specifications
Phase
DCA-220SSVU— DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
TABLE 3. DIMENSIONS
Dimension ft. mm
DCA-220SSVU— SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
Whisperwatt Generator
DCA-220SSVU— SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEEDCONDITIONS
General Safety
DCA-220SSVU— RULES FOR SAFE OPERATION
DANGER - READTHIS MANUAL
Electrical Safety
DCA-220SSVU— RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
Maintenance Safety
Battery Safety
DANGER - EXPLOSION HAZARDS
DCA-220SSVU— RULES FOR SAFE OPERATION
Towing &Transporting Safety
Emergencies
DCA-220SSVU— RULES FOR SAFE OPERATION
DCA-220SSVU— GENERATOR DECALS
Figure 2. Generator Decals
DCA-220SSVU- GENERATOR DECALS
Figure 3. Generator Decals Cont inued
DCA-220SSVU— INSTALLATION
Figure 4.Typical Generator Grounding Application
DCA-220SSVU— INSTALLATION
Outdoor Installation
Indoor Installation
CAUTION - EXHAUST HAZARD
DCA-220SSVU— GENERAL INFORMATION
Generator
Engine Operating Panel
Generator Control Panel
DCA-220SSVU— MAJOR COMPONENTS
Figure 5. Major Components
Output Terminal Panel Assembly
Output Receptacles Assembly
NOTE PAGE
DCA-220SSVU— GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
DCA-220SSVU— ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
DCA-220SSVU— ENGINE OPERATING PANEL
11.Auto On/Off Engine Controller MPEC –
Output Terminal Familiarization
Figure 8. Output Terminal Panel
Output Terminal Panel
100VAC GFCI Receptacles
Figure 9. G.F.C.I. Receptacle
Figure 11. Voltage Regulator Control Knob
Figure 10. 120/240V Twist-Lock
Connecting Loads
Figure 13. Connecting Loads
Over Current Relay
Figure 14. Over Current Relay
Single Phase Load
Table 5. Power Factor By Load
Three Phase Load
DCA-220SSVU— LOAD APPLICATION
DCA-220SSVU- GENERATOR OUTPUTS
Table 9. Generator Ampere Ratings ⎯ 3∅
Generator OutputVoltages
Voltage Change-OverBoard
How to Read the Output Terminal Gauge
Change-OverSwitch
DCA-220SSVU— GENERATOR OUTPUTS/ GAUGE READING
Maximum Amps
DCA-220SSVU— OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240VUVWO Terminal Output Voltages
1Ø-240VUVWO Terminal Output Voltages
DCA-220SSVU— OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480VUVWO Terminal Output Voltages
1Ø-480VUVWO Terminal Output Voltages
1Ø-277VUVWO Terminal Output Voltages
DCA-220SSVU- PRE-SETUP
Circuit Breakers
Lubrication Oil
Fuel Check
DCA-220SSVU— PRE-SETUP
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
Figure 33. Fueling the Generator
Cleaning the Radiator
Air Cleaner
Table 12. Coolant Capacity
Operation FreezingWeather
Battery
Battery Cable Installation
Figure 37. Battery Connections
CAUTION - BATTERY SERVICING SAFETY
DCA-220SSVU— GENERATOR START-UPPROCEDURE MANUAL
Figure 41. Engine Speed Switch Low
Figure 42. MPEC Control Switch Manual Position
Figure 43. Engine Speed Switch High
Figure 50. Coolant Temperature Gauge
Figure 47.Voltage Adjust Control Knob
Figure 45. Frequency Meter Hz
Figure 46. Voltmeter
CAUTION - BACKUP GENERATOR USE
Figure 54. Engine Speed Switch High
Figure 55. MPEC Control Switch AUTO
WARNING - AUTO MODE MAINTENANCE
DCA-220SSVU— GENERATOR SHUT-DOWNPROCEDURES
Normal Shutdown Procedure
Figure 56. Engine Speed Switch Low
Emergency Shutdown Procedure
DCA-220SSVU— MAINTENANCE
TABLE 14. INSPECTION/MAINTENANCE
Air Cleaner with Dust Indicator
Service Daily
Cleaning the Fuel Strainer
Air Removal
Check Oil Level
Replacing Oil Filter
DCA-220SSVU- MAINTENANCE
To ensure adequate starting
DCA-220SSVU —TRAILERMAINTENANCE
Trailer Maintenance
DCA-220SSVU —TRAILERMAINTENANCE
Brake Adjustment
Brakes
Hydraulic Surge Brakes
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
TireWear/Inflation
Suspension
DCA-220SSVU —TRAILERMAINTENANCE
Lug Nut Torque Requirements
Figure 61. Wheel Lug Nuts Tightening Sequence
Table 18. Tire Torque Requirements
DCA-220SSVU —TRAILERWIRINGDIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
DCA-220SSVU— GENERATORWIRING DIAGRAM
Figure 63. Generator Wiring Diagram
DCA-220SSVU— ENGINEWIRING DIAGRAM
Figure 64. Engine Wiring Diagram
DCA-220SSVU —TROUBLESHOOTINGGENERATOR
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
DCA-220SSVU —TROUBLESHOOTINGENGINE CONTROLLER
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
SYMPTOM
POSSIBLE PROBLEM
NO. Column
PART NO. Column
QTY. Column
REMARKS Column
DCA-220SSVU— SUGGESTED SPARE PARTS
Part number on this Suggested Spare Parts list
Description
DCA-220SSVU— GENERATOR ASSY
GENERATOR ASSY
PART NO
PART NAME
REMARKS
DCA-220SSVU— GENERATOR ASSY
DCA-220SSVU— GENERATOR ASSY. CONT
DCA-220SSVU— GENERATOR ASSY. CONT
PART NO
PART NAME
0012110065
DCA-220SSVU—CONTROL PANEL ASSY
CONTROL PANEL ASSY
DCA-220SSVU—CONTROL PANEL ASSY
PART NAME
REMARKS
DCA-220SSVU—CONTROL BOX ASSY
CONTROL BOX ASSY
DCA-220SSVU—CONTROL BOX ASSY
CONTROL BOX ASSY
PART NO
PART NAME
DCA-220SSVU—CONTROL BOX ASSY. CONT
CONTROL BOX ASSY. CONT
DCA-220SSVU—CONTROL BOX ASSY. CONT
CONTROL BOX ASSY. CONT
PART NO
PART NAME
DCA-220SSVU—ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
DCA-220SSVU—ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NO
PART NAME
DCA-220SSVU—ENGINE AND RADIATOR ASSY
DCA-220SSVU—ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PART NO
PART NAME
DCA-220SSVU—OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
DCA-220SSVU—OUTPUTTERMINAL ASSY
PART NO
PART NAME
M4230700003
DCA-220SSVU-BATTERY ASSY
BATTERY ASSY
DCA-220SSVU-BATTERY ASSY
BATTERY ASSY
PART NO
PART NAME
DCA-220SSVU—MUFFLER ASSY
MUFFLER ASSY
DCA-220SSVU—MUFFLER ASSY
MUFFLER ASSY
PART NO
PART NAME
DCA-220SSVU—FUELTANK ASSY
FUEL TANK ASSY
DCA-220SSVU—FUELTANK ASSY
FUEL TANK ASSY
PART NO
PART NAME
DCA-220SSVU—ENCLOSURE ASSY
ENCLOSURE ASSY
DCA-220SSVU—ENCLOSURE ASSY
ENCLOSURE ASSY
PART NO
PART NAME
DCA-220SSVU—ENCLOSURE ASSY. CONT
ENCLOSURE ASSY. CONT
DCA-220SSVU—ENCLOSURE ASSY. CONT
ENCLOSURE ASSY. CONT
PART NO
PART NAME
DCA-220SSVU—RUBBER SEALS ASSY
RUBBER SEALS ASSY
DCA-220SSVU—RUBBER SEALS ASSY
PART NO
PART NAME
0229201300
DCA-220SSVU-NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
DCA-220SSVU—NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
PART NO
PART NAME
TERMS AND CONDITIONS OF SALE — PARTS
SPECIAL EXPEDITING SERVICE
2.ToobtainaReturnMaterialAuthorization
Effective:October 1,
NOTE PAGE
HERES HOW TO GET HELP
NUMBER ON-HAND WHEN CALLING
SERVICE DEPARTMENT
WARRANTYDEPARTMENT