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Multiquip C1870300404 Portable Generator User Manual

1. HOSE BAND BEOWBI HOSE uuu us s BEOVIBY HO E x xs HOSE BAND u BAND HOSE GUIDE HEX HEAD BOLT DRAIN VALVE LEAK OFF LINE HEX HEAD BOLT TOOTHED WASHER COOLANT LEVEL SWITCH CLAMP CLAMP RADIATOR PIPE DCA220SSUU RADIATOR HOSE DCA220SSJU RADIATOR HOSE DCA220SSJU VENT HOSE DCA220S5SJU RADIATOR PIPE DCA220SSUU ENGINE WIRE HARNESS ALTERNATOR FAN BELT STARTER 22055 0 THERMOSTAT QTY 1 REMARKS DCA22088J Re DCA220SSJU DCA220SSJ DCA220SSJU DCA220SSJ DCA220SSJU aes DCA220SSJ DCA220SSJU DCA220SSJ DCA220SSJU REPLACES P N 0602123290 S N 8010011 AND ABOVE eee S N 8010011 AND ABOVE m S N 8010011 AND ABOVE oci S N 8010011 AND ABOVE S N 8010011 AND ABOVE ost REPLACES P N RE509025 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 87 OUTPUT TERMINAL ASSY DCA220SSJ SSJU pu ss N gt E gt Lu cc lt lt lt o lt lt lt lt H lt t cc Lu a gt 9 42
2. 78 81 Engine and Radiator Assembly 82 87 Output Terminal Assembly 88 91 Battery Assembly 92 93 Muffler Assembly 94 95 Fuel Tank Assembly 96 97 Enclosure Assembly 98 105 Rubber Seals Assembly 106 107 Nameplate and Decals 108 111 Terms and Condition of Sale Parts 112 NOTICE Specification and part number are subject to change without notice PAGE 4 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective January 15 2006 Order via Internet Dealers Only If you have MQ Account to obtain a Username Order parts on line using Multiquips SmartEquip website and Password E mail at parts multiquip View Parts Diagrams com Order Parts To obtain an MQ Account contact your District Sales Manager for more information li Print Specification Information es 7 Goto www multiquip com and click on Use the internet and qualif
3. 60 0016908020 HEX HEAD BOLT 61 M4383000104 PIPE AIR CLEANER 62 0602040365 90 ELBOW 63 0605515260 HOSE BAND 64 0602022580 ADAPTER 65 0602022561 90 ELBOW 66 0603306590 CONNECTOR 67 0603300285 LOCK NUT 68 0605511395 VALVE 69 0603306395 HOSE JOINT DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 85 1 1 6 4 1 1 1 1 9 1 1 1 1 3 9 1 1 1 1 1 5 3 1 2 1 1 1 1 1 1 1 1 1 2 2 4 4 1 4 1 1 3 1 1 1 1 1 1 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY 64 65 6968 66 67 70 VIEW Z 5 81 44 4 39 93 38 V A ELM j ie ee LL 44 46 al E PAGE 86 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 0 0602021070 0269200660 0802081003 M9300000203 0602010900 M4316100103 0016910025 0199901500 0199101850 0193601600 0193601250 0193600700 0605515106 0191601700 0191601400 0605515174 0605515149 M4483600003 0016908020 0602017090 0602042601 0017110020 0040510000 813NLUOOO0T 0602220911 0602220910 M4310401104 M4310501603 M4310501503 0199100830 0605515189 0602202452 RE533516 0602015230 RE523502 RE527018 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY PART NAME CAP DRAIN HOSE RESERVE TANK RESERVE TANK CAP RESERVE TANK BRACKET HEX HEAD BOLT
4. DCA220SSu 4 M4363200104 E DCA220SSu 5 0805003414 SUPPORTER SHEEI E DCA220SSu 6 0016908020 HEX HEAD BOLT LM DCA220SSu 7 0207308000 U u 2 DCA220SSu 8 0222100120 m Poenus DCA220SSu 9 0222100180 RUBBER sunu mana NE DCA220SSu 10 0130206000 STREET ELBOW pcm DCA220SSu 11 8085512104 LONG NIPPLE oneee a ge DCA220SSu 12 0603325011 VALVE LO DCA220SSu 13 0132006000 PLOC T prem DCA220SSu 14 0191302200 SUC NON FOSE E DCA220SSu 15 0191302800 RETURN HOSE sesana an uu DCA220SSJ 16 0605515109 HOSE BAND uuu u aa DCA220SSu 17 M4363000102 e ER DCA220SSJU 18 0605505070 TU Le DCA220SSJU 19 0605501069 glia GAUGE SENDER uuu u eT p DCA220SSJU 20 0605516090 Cis a eee u uum DCA220SSJU 21 0027104016 MACHINE SCREW uu u u DCA220SSJU 22 M4363200104 DANO DCA220SSJU 23 M9310500104 SUPPORTER DCA220SSJU 24 0016908020 AHEAD BOLT u uu u us D raum DCA220SSJU 20 0207308000 SUPER LOCK qti DCA220SSJU 26 0222100120 DCA220SSJU 27 0222100180 HUBBSSHSHEBI LS
5. ara s s SEALE WIRE DX FULL LEVEL UNIT SIDE 127 pO za N FUEL LEVEL UNI 4 e e c USED BESSER sa p rr lt l P 73447 33330 PAGE 66 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 shown below for diagnosis of the Generator If the problem cannot be remedied consult our company s business office or service plant TABLE 19 GENERATOR TROUBLESHOOTING DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 67 DCA 220SSJ SSJU TROUBLESHOOTING ENGINE CONTROLLER Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 20 Engine Controller Troubleshooting as a basic guideline for troubleshooting the Microprocessor Engine Controller unit MPEC If the problem cannot be remedied consult our company s business office or service plant TABLE 20 ENGINE CONTROLLER TROUBLESHOOTING MPEC SYMPTOM POSSIBLE PROBLEM SOLUTION Low oil level Fill oil level Low oil pressure light is Oil pressure sending unit failure Replace oil pressure sending unit n Time delay malfuntion in Controll
6. A CAUTION BATTERY SERVICING SAFETY Inadequate battery connections may cause poor starting of the generator and create other malfunctions Alternator The polarity of the alternator is negative grounding type When an inverted circuit connection takes place the circuit will be in short circuit instantaneously resulting the alternator failure DO NOT put water directly on the alternator Entry of water into the alternator can cause corrision and damage the alternator Wiring Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 51 DCA 220SSJ SSJU GENERATOR START UP PROCEDURE MANUAL Before Starting A CAUTION LETHAL EXHAUST HAZARD The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel A WARNING STARTING THE GENERATOR NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position The Engine Control Unit ECU used with this generator dia
7. DCA220858J 6 DCA220SSJU 5 5 DCA220SSJ 5 DCA220SSJU 25 9 DCA220858J DCA220SSJU 11 E 1 DCA22088JU 1 DCA22088JU massa 4 S N 8010011 AND ABOVE DCA220SSJ THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING A PAINTED PANEL OF A DIFFERENT COLOR MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 105 DCA220SSJ SSJU RUBBER SEALS ASSY 22055 ONLY PAGE 106 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 NED ON O PART NO 0229201240 0228900945 0228901200 0228901260 0228901055 0228900600 0228900660 0229201060 0229200660 0228801050 0228801050 0228800595 0228800635 0229400635 0228100560 0228100370 0229201020 0228301200 0229201020 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER DCA220SSJ SSJU RUBBER SEALS ASSY QTY N Rona REMARKS DCA220SSu DCA220SSJU DCA220SSu DCA220SSJU DCA220SSJU DCA 220SSJ S
8. 3 DCA220SSJU 10 22055 10 22055 10 1 8 DCA220858J 8 DCA220SSJU 1 2 2 2 DCA220SSJ 2 DCA220SSJU 2 1 Q 4 DCA220SSJ 4 DCA220SSJU 1 1 2 22055 2 DCA220SSJU 4 DCA220SSJU DCA220SSJ THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING A PAINTED PANEL OF A DIFFERENT COLOR MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 91 DCA220SSJ SSJU BATTERY ASSY DCA220SSJ DCA220SSJU PAGE 92 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU BATTERY ASSY NO PART NO PART NAME QTY REMARKS 1 0168614551 siglo ls a DCA220SSJ 2 C9109100604 BAI TERY SHEELu S tam EIS EIER UIDES nemen DCA220SSu 3 0805000904 BATTERY DCA220SSu 4 0805002904 BATTERY uu uu DCA220SSJ 5 0037808000 E sien E ZR DCA220SSu 6 0040008000 COCK DCA220SSu 7 0041608000 UA SHE TL Luz uu u E DCA220SSJ 8 C1346600004 BATERY CABLE UO
9. 44 46 al E PAGE 82 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY NO PART NO PART NAME QTY REMARKS 1 M4923200034 ENGINE JOHN DEERE 6068HF485 1 1 1 0602041292 OIL FILTER CARTRIDGE OIL FILTER RE504836 1 2 0602042596 PRIMARY FUEL FILTER CARTRIDGE used RE529643 1 3 0602042597 FINAL FUEL FILTER CARTRIDGE m RE522878 2 0602060015 BLOWER asta 4735 42599 02 3 0602061003 FAN SPACER R81876 4 0012110110 HEX HEAD BOLT 4 5 0042510000 WASHER LOCK 4 6 M3303200404 ENGINE FOOT 2 7 0010312030 HEAD BOLT 6 8 0042512000 WASHER 4 DCA220SSu 8 0040012000 WASRER COOK 4 DCA220SSJU 9 0605000011 RUBBER SUSPENSION 2 10 0030016000 HEX NUT 4 11 0040016000 WASHER LOCK 4 12 M4923200014 RADIATOR 1 12A 4493601304 ACOUSTIC SHEET 2 13 0602011062 CAP 1 14 M9200101004 ADAPTOR 1 15 0150000016 O RING 1 16 M4310201103 SUPPORT RADIATOR 1 17 M4310201203 SUPPORT RADIATOR 1 4493601504 ACOUSTIC SHEET 1 18 0016908020 HEX HEAD BOLT 16 19 M4310600304 RUBBER SHEET 2 20 0010112060 DCA220SSu 20 0017112055 HEX HEAD BOLT 4 DCA220SSJU 21 0030012000 HEX NUT 8 22 0041212000 WASHER FLAT 8 23 M4310200904 BRACKET RADIATOR 2 24 0016910025 HEX HEAD BOLT 4 25 0016910025 HEX HEAD BOLT 2
10. OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Ouput Terminal Lugs or the convienience receptacles Figure 14 Make sure to read the operation manual before attempting to connect a load to the generator To protect the output terminals from overload a 3 pole 600A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine CS 6369 TWIST LOCK RECEPTACLES HARD WIRE HOOKUP PANEL LOAD 9 RECEPTACLE GROUND LOAD NEUTRAL Figure 14 Connecting Loads Over Current Relay An over current relay Figure 15 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated in the control box Figure 15 Over Current Relay PAGE 42 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage frequency and voltage requirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require
11. AVAVAVAVAVAVAM MU WE ACCEPT ALL MAJOR CREDIT CARDS DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 5 DCA 220SSJ SSJU SPECIFICATIONS Table 1 Generator Specifications Model 06 2209888 0 Revolving field self ventilated open protected type synchronous generator Power Factor 08 Table 2 Engine Specifications Model DEERE 6068HF485 4 cycle water cooled direct injection turbo charged air air 13 63 gal 51 6 L hr at full load PAGE 6 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU DIMENSIONS TOP SIDE AND FRONT TOP VIEW TABLE 3 DIMENSIONS pod Dimension ft mm Reference Letter Dimension ft mm 3 00 in 940 mm 137 80 in 8 500 mm BO 37 00 in 940 mm 66 92 in 1 700 mm 41 33 n 1060 mm 4881 in 1240 mm 41 33 in 1 050 mm 4135 1050 mm Figure 1 Dimensions DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 7 DCA 220SSJ SSJU SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY ANDTHE SAFETY OF OTHERS Safety precautions should be followed at all times when operating this equipment Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others This Owner s Manual has been developed to p
12. CE OSD OD NAD PP NN CO DCA220SSJ THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING A PAINTED PANEL OF A DIFFERENT COLOR MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED REMARKS DCA220SSu SSJU ENCLOSURE ASSY PAGE 104 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PART NO 9113000102 0021806016 0030006000 M4453600004 M4453600104 0019206016 0845046904 0845045004 M9116100004 0845047004 0845045004 M9116100004 0019208020 0601850097 0025408025 0027208025 0845031504 0016908020 0040508000 0019210025 DCA220SSu SSJU ENCLOSURE ASSY PART NAME DOOR HANDLE MACHINE SCREW HEX NUT GUTTER GUTTER HEX HEAD BOLT HINGE HEX HEAD BOLT STOPPER MACHINE SCREW MACHINE SCREW BLIND PLUG HEAD BOLT TOOTHED WASHER HEX HEAD BOLT DCA220SSJU DCA220SSJU ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED QTY REMARKS 3 28 28 3 2 15 6 6
13. P vision DCA220SSJU 28 M9200000003 BRNO DCA220SSJU 29 M9200200004 DCA220SSJU 30 0150000018 oc m DCA220SSJU 31 0016906020 HEX HEAD BOLT l eee DCA220SSJU 32 M1363400104 DRAIN HOSE pem DCA220SSJU 33 0605515198 BAND DCA220SSJU 34 0191302800 u umm DCA220SSJU 35 0191302200 HEIDBINTIOSE E DCA220SSJU 36 0605515109 BAND x ua ert shaspan DCA220SSJU DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 97 DCA220SSJ SSJU ENCLOSURE ASSY PAGE 98 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 O 4 00 gt gt gt gt PART NO C1413004402 M4413000302 M4413400404 M1413400004 0019208020 M4423000302 4423000312 4493102503 4493102513 M4423000402 4423000412 4493102503 4493102513 0016908020 0019210035 0016910025 4423200304 4493102704 0019208020 4423200403 0019208020 M4423300004 M4423300014 M4493601404 M4493601414 M4423300104 M4423300114 M4493601404 M4493601404 0019206020 0016906016 M4423200204 M4493102604 0019208020 M4433000102 M4493200104 0010114050 0010114040 DCA220SSJU DCA220SSJ SSJU ENCLOSURE ASSY PART NAME QTY REMARKS M sss a DCA220SSJ
14. DCA220SSJU jm S N 8010166 AND ABOVE 17 0027105016 MACHINE SCREW 4 18 0601820847 OVER CURRENT RELAY 1 19 0601820848 OVER CURRENT RELAY 1 20 0027104016 MACHINE SCREW 2 20A 0207004000 HEX NUT 2 21 M4260600304 BRACKET DIAGNOSTIC GAUGE 1 22 0016908020 HEX HEAD BOLT 2 23 0602120690 POWER VIEW 1 24 0601831330 DIAGNOSTIC SWITCH 1 20 0601813977 RECEPTACLE 1 25A 0601812891 DUST CAP 1 20B 0601812890 STRAIN RELIEF 1 26 M4260500003 SET PANEL ELECTRIC PARTS 1 27 0016908020 HEX HEAD BOLT 4 28 0602202592 STARTER RELAY 1 29 0027106016 MACHINE SCREW aqnis ipaa text Pone DCA220SSu 29 0027103015 MACHINE SCREW race DCA220SSJU 29A 0030003000 NE DCA220SSJU 29B 0041203000 DRAIN WASHER seen DCA220SSJU DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 79 DCA220SSu SSJU CONTROL BOX ASSY CONT PAGE 80 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 0 LY2DUS12VDC 1 0027104020 0601821370 0027104020 M4260600404 0016906016 M4266600004 020106050 0027106020 0601802218 0601806653 0601802149 0027103020 0601815154 0027104016 3871824004 M4213600104 0041206000 0605010502 M4213500104 0016908020 M4213400104 0016908020 0226900300 0330000300 0226900215 0330000215 0017110040 0016908020 0207010000 0016908020
15. DCA220SSJU OOVER DCA220SSu OOVER DCA220SSJU HEX HEAD BOLT 4 FRONT PRAMME sesape u UR DCA220SSu FRONTE RANE e ux uy DCA220SSJU ACOUSTIC SREE L uu u uu deu ME pm DCA220SSu PCOUSTIG GHEE u jm DCA220SSJU FAO I EP VIE DCA220SSu FRONTE RA NE L u spends DCA220SSJU AGOUSTIO SAE E pe DCA220SSu POOUSTIG CHEE I DCA220SSJU HEX HEAD BOLT 10 PIE EAL BODDU uuu u u u uu u DCA220SSu HEX e 8 DCA220SSJU COVER FRONT FRAME 1 ACOUSTIC SHEET 1 HEX HEAD BOLT 6 OVER COVER FRONT FRAME 1 HEX HEAD BOLT 14 DISCHARGE GUIDE Ua tatu Ja DCA220SSJ DISCHARGE GUIDE DCA220SSJU AGOUS IO SHEE DCA220SSu ACOUSTIC SHEE T uuu yana DCA220SSJU DISOFrIARGEGUIDDEu lll DCA220SSu DISOrARGEGUIDE uu u l u u u DCA220SSJU SHEE Ni ERR j DCA220SSu PCOUSTIC SHEEN u yunus ana DCA220SSJU HEX HEAD BOLT 12 DCA220SSu HEX HEAD BOLT uuu a DCA220SSJU FRONT FRAME COVER 1 ACOUSTIC SHEET 1 HEX HEAD BOLT 10 CENTER FRAME 1 ACOUSTIC SHEET 1 HEX HEADIBOLI soni nti anii pe n Rue ama tacts DCA220SSu HEX HEAD u uu EDDIE A DCA220SSJU DCA220SSJ ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORD
16. Indicates the engine temperature has exceeded 239 F The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of times and has failed to start The number of cycles and duration are programmable It is pre set at 3 cycles with a 10 second duration This is considered a major fault Overspeed Shutdown Indicates the engine is running at an unsafe speed This is considered a major fault Engine Running Indicates that engine is running at a safe operating speed DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 39 DCA 220SSJ SSJU OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization The Output Terminal Panel Figure 9 shown below islocated The Output Terminal Panel Figure 8 is provided with the on the right hand side left from control panel of the generator following Lift up on the cover to gain access to receptacles and terminal Three 3 120 240V output receptacles 50 amp lugs Three 3 Circuit Breakers 50 amps Two 2 100V GFCI receptacles 20 amp NOTICE Terminal legs and Ground are considered bonded Two 2 GFCI Circuit Breakers 20 amps grounds Five 5 Output Terminal Lugs U V W O Ground 2 NEUTRAL GROUND OUTPUT TERMINALS T
17. MUFFLER ASSY NO PART NO PART NAME QTY REMARKS 1 M4330100602 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M4333000303 EXHAUST PIPE 1 4 0602325066 CLAMP 1 5 M4333200004 GASKET 1 6 0010112055 HEX HEAD 4 DCA220SSJ 6 0017112055 HEX HEAD BOLT 4 DCA220SSJU 6A 0040012000 WASHEHSEOUNR uscite u u 4 DCA220SSJ 6B 0041212000 WASHER FLAT M NE DCA220SSu 7 M4330300004 COVER 2 8 0016908020 HEX HEAD BOLT 4 9 M4333300304 BRACKET 1 10 0016908020 HEX HEAD BOLT 4 11 0602326062 U BOLT SET 1 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 95 FUEL TANK ASSY gt gt e CN CN T Q A DCA220SSJ DCA220SSJU pu ss N gt E gt Lu cc lt lt lt o lt lt lt lt H lt t cc Lu a gt 9 42 9 CN c t e Lu lt DCA220SSJ SSJU FUEL TANK ASSY NO PART NO PART NAME QTY REMARKS 1 C1363001403 uM C lassen DCA220SSu 1 1 0845500104 SUN DCA220SSu 1 2 0810105400 PUL FIED ET DCA220SSu 2 0605501092 FUEL GAUGE SENDER uuu uu umm DCA220SSu 2A 0605516090 OPORE HA DCA220SSu 3 0022905015 MACHINE SORE L u uuu
18. 02 28 14 PART NO M4463200202 M4493501903 M4463200403 M4493502004 0016908020 M4463400003 0016908020 M4463200304 0016906020 0016906016 M4465300204 0019206016 0019208020 M4453200102 4493403604 0019108065 0042308000 0042408000 M4453001203 M4493403804 M4453001303 4493403904 M4453001003 M4493403004 M4453001 103 M4493403104 M4453301004 M4493404004 M4453300504 M4493403204 M4453300704 M4493403404 M4453300804 M4493403504 0207008000 B9114000002 DCA220SSJ SSJU ENCLOSURE ASSY PART NAME ROOF PANEL ACOUSTIC SHEET REAR ROOF DUCT ACOUSTIC SHEET HEX HEAD BOLT DUCT COVER HEX HEAD BOLT COVER HEX HEAD BOLT HEX HEAD BOLT GUTTER HEX HEAD BOLT HEX HEAD BOLT SPLASHER PANEL ACOUSTICSHEET HEX HEAD BOLT WASHER LOCK WASHER FLAT SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT DOOR HANDLE DCA220SSJU ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 103 QTY S SS SS S
19. Once the Wait to start message 1 no longer displayed the operator may start the engine Note Displays only when SAE J1939 message is supported by engine manufacturer WAIT TO START PREHEAT Once the engine has started the single engine parameter is displayed Main Menu Navigation Starting at the single or four engine parameter display touch Menu 3 4 The first seven items of the Main Menu will be displayed Touching the Arrow Buttons will scroll through the menu selection Touching the right arrow button will scroll down to reveal the last items of Main Menu screen highlighting the next item down ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES Touch the Arrows to scroll to the desired menu item or touch Menu to exit the Main menu and return to the engine parameter display 1800 RPM SNENA COOL TEMP Selecting a Language 1 Starting at the main menu display use the Arrows to scroll to the Language menu and once highlighted touch the Enter button GO TO 1 UP DISPLAY LANGUAGES STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 21 DCA 220SSu SSJU DIAGNOSTIC DISPLAY 2 Thelanguage choices will be displayed Use the 4 buttons to scroll through the selections and touch Enter to make a selection
20. Open cabinet doors on the right side of the generator 4 from generator control panel position Remove fuel cap A WARNING RESPIRATORY HAZARDS and fill tank Figure 33 Diesel fuel and its vapors are dangerous Mi to your health and the surrounding 5 25 environment Avoid skin contact and or inhaling fumes WHISPERWATT Pes Figure 33 Fueling the Generator FUEL TANK 1 Level Tanks Make sure fuel cells are level with the FILLER PORT ground Failure to do so will cause fuel to spill from the tank before reaching full capacity Figure 32 DIESEL FUEL ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank DO NOT fill on unlevel ground 3 NEVER overfill fuel tank It is important to read the m cro fuel gauge when filling trailer fuel tank DO NOT wait for Level Ground fuel to rise in filler neck Figure 34 Figure 32 Only Fill on Level Ground a ON CONTROL PANEL NOTICE O ONLY use 2 diesel fuel when refueling SOA OD A OL OL On OD OL OL ON OF On OL Of OL OL Oh ON OL OF 8 OL OL 00 Figure 34 Full Fuel Tank A CAUTION REFUELING THE GENERATOR DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 35 Fuel EXPANDS When Heated Figure 35 Fuel Expansion DCA 220SSJ SSJU OPERATION AND PARTS
21. When the engine demand increases or decreases the governor system regulates the frequency variation to 25 Extension Cables When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size PAGE 18 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU MAJOR COMPONENTS Figure 5 Major Components Table 4 Generator Major Components s Cs eese a DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 19 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Figure 6 Diagnostic Display Panel The diagnostic display panel located inside the control box on the generator Figure 6 is designed to meet the needs for instrumentation and control of electronically controlled engine communication using the SAEJ1939 Controller Area Network CAN This diagnostic display is a multifunction tool that enables equipment operators to view many different engine parameters and service codes The keypad on the diagnostic display panel is a capacitive touch sensing system There are no mechanical switches to wear or stick This keypa
22. of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts AX CAUTION EXHAUST HAZARD Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Indoor Installation Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves Mounting The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to NFPA 110 Chapter 5 4 1 DO NOT remove the metal skids on the bottom of the generator They are to resist damage to the bottom of the generator and to maintain alignment Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Elec
23. 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment If wattage is not given on the equipments name plate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load single phase induction motors 0 4 0 75 Electric heaters incandescent 10 lamps Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Table 6 Cable Selection 60 Hz Single Phase Operation Load In Watts Maximum Allowable Cable Length Current in Amperes At 100 At 200 Volts Volts as aw e wx coon aren zon s sm soon aon mon sn 75 wo aon aon 1200 2400 250 ft 150 ft 100 ft 1800 3600 150 ft 100 ft CAUTION Equipment damage can result from low voltage Three Phase Load When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 KVA z NOTICE If 30 load kVA is not given on the equipment nameplate approximate 30 load output maybe determined by multi plying voltage by amperage by 1 732 NOTICE Motors and motor driven equipment draw much greater current for starting t
24. A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used quantity can be indicated by a number a blank entry or A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by SIN XXXXX AND BELOW SIN XXXX AND ABOVE SIN XXXX TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by ONLY NOT USED ON XXXX Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery
25. DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations Always allow sufficient time for the engine and generator to cool before performing maintenance Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to gush out of the radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the coolant plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug therefore causing severe scalding to any persons in the general area of the generator Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator Battery Safety Use the following guidelines when handling the battery The battery contains acids that can cause injury to the eyes and skin To gt avoid eye irritation always wear safety gt glasses Use well insulated gloves when picking up the battery DANGER EXPLOSION HAZARDS The risk of an explosion exists when performing service on the battery To avoid severe injury or DEATH DO NOT drop the battery There is the possibility of risk that the battery may explode DO NOT expose t
26. MANUAL REV 1 02 28 14 PAGE 49 DCA 220SSJ SSJU SETUP Coolant Antifreeze John Deere recommends Antifreeze Summer Coolant for use in thier engines which can be purchased in concentrate and mixed with 50 demineralized water or pre diluted See the John Deere Engine Owner s Manual for further details AX WARNING BURN HAZARDS If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled possibility of hot coolant exists which can cause severe burns Day to day addition of coolant is done from the recovery tank When adding coolant to the radiator DO NOT remove the radiator cap until the unit has completely cooled See Table 12 for engine radiator and recovery tank coolant capacities Make sure the coolant level in the recovery tank is always between the and the L markings Table 12 Coolant Capacity Engine and Radiator 6 4 Gal 24 liters Reserve Tank 2 Quarts 1 9 liters Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Freezing Point Vol Anti Freeze NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodi
27. OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 25 DCA 220SSu SSJU DIAGNOSTIC DISPLAY 5 indicates Auxiliary Gage Fault A Indicates Fault Warning p Indicates Derate or Shutdown Condition Fault Touching the Enter Button will redisplay the hidden fault Touching the Enter Button once again will hide the fault and return the screen to the single or four parameter display NOTE The fault can only be cleared by correcting the cause of the fault condition 1ofx ENGINE OIL PRESSURE Active Fault Codes 1 During normal operation the single or four parameter screen will be displayed When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the Active Fault Codes message If the word MORE appears above the Arrow Buttons there are more active fault codes that may be viewed Use the Arrow Buttons to scroll to the next Active Fault Code 4 To acknowledge and the fault and return to the single or four parameter display touch the Enter Button The display will return to the single or four parameter display but the display will contain the Active Fault warning icon Touching the Enter Button will redisplay the hidden fault 6 Touching the Enter Button once again will hide the fault and return the screen to the single or
28. SSJU NAMEPLATE AND DECALS ASSY CONT PART NO 0800689504 M9500300004 0800689404 M9500300104 C9505300004 M9510100403 B9504200004 M9503200004 1320620904 M9500500004 6360620004 M9500500104 0840625902 M9510200002 0600500090 0021106016 C1560100303 M4560101103 C0560100403 M4560101203 C1560100204 M4560100904 C1560100404 M4560101304 C1560100004 M4560100704 C1560100103 M4560100803 C0560100303 M4560101003 M9503200104 M3550002204 M9510000104 920214100 PART NAME QTY REMARKS BATTERY GROUP DEGA pm 92091 22055 DEGAT ss M90030000 DCA220SSJU DEGAT jm 52090 22055 DEGAU unanqa M90030010 DCA220SSJU DECAL C90530000 DCA220SSJ DECAL CAUTION M eee M91010040 DCA220SSJU MUFFLER GROUP DECAL WARNING ENGINE EXHAUST jm B90420000 DCA22088J DECAL WARNING ENGINE EXHAUST M90320000 DCA220SSJU FUELTANK GROUP DECAL DIESEL FUEL jr 91756 DCA220SSJ DECAL DIESEL FUEL socero asas aan M90050000 DCA220SSJU DECAL POEL OR Torn 91883 22055 DECAL FUEL DRAIN PLUG uu ees M90050010 DCA220SSJU ENCLOSURE GROUP DEGA EMO ree eee teen ene jg 93057 DCA220SSJ DO P jc M91020000 DCA220SSJU EMBLEM 2 MACHINE SCREW 4 STRIPE 1 DCA220SSJ STRIPE jm DCA220SSJU STRIPE jm DCA22088J STRIPE DCA2
29. Suspension Components Tire Wear Inflation Tire inflation pressure is the most important factor in tire life Table 17 Suspension Torque Requirements Pressure should be checked cold before operation DO NOT bleed air from tires when they are Check inflation ttem Torque pressure weekly during use to insure the maximum tire life and tread wear Table 16 Tire Wear Troubleshooting will help pinpoint the Causes and solutions of tire wear problems 1 2 U BOLT TABLE 16 TIRE WEAR TROUBLESHOOTING SHAKE ROIT SNUG FIT ONLY PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED CAUSE SOLUTION SPRING EYE BOLT NEAR PATTERN RETAIN NUT BOLT ASSEMBLY Adjust pressure to Center Wear Over Inflation particular load per tire mianufaeturer SHOULDER TYPE MIN 30 MAX 50 Adjust pressure to SHACKLE BOLT Edge Wear Under Inflation i i particular load per tire manufacturer Side Wear Loss of camber 22 ien or overloading 9 Alian wheels AM Check bearing adjustment Cuppin Out of balance Wheel lockup amp Avoid sudden stops when aa tire skidding possible and adjust brakes PAGE 62 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU MAINTENANCE TRAILER Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to t
30. and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas DO NOT place hands or fingers inside generator engine compartment when engine is running NEVER run engine without air filter Severe engine damage may occur DO NOT leave the generator running in the manual mode unattended Refer to the John Deere Engine Owner s Manual for engine technical questions or information ALWAYS store equipment properly when it is not being used Equipment should be stored in a clean dry location out of the reach of children PAGE 10 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU RULES FOR SAFE OPERATION Generator Grounding To guard against electrical shock and possible damage to the equipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical The following safety recommendations should also be followed ALWAYS make sure generator is properly grounded NEVER use gas piping as an electrical ground ALWAYS make sure that electrical circuits are properly grounded per the National Electrical Code NEC and local codes before operating generator Severe injury or DEATH by electro
31. both cocks located at the crankcase side and at the lower part of the radiator and drain coolant Open the radiator cap while draining Remove the overflow tank and drain e Check hoses for softening and kinks Check clamps for signs of leakage e Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed DO NOT clean radiator core with any objects such as a screwdriver e Tighten both cocks and replace the overflow tank e Replace with coolant as recommended by the engine manufaturer e Close radiator cap tightly Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or eQ steam Generator Storage For longe term storage of the generator the following is recommended e Fill the fuel tank completely Treat with a fuel stabilizer if necessary e Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire generator internal and external Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level If generator is mounted on a trailer jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires PAGE 58 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU MAINTENANCE HEATER CHARGER Jacket Wa
32. four parameter display The Single or Four parameter screen will display the fault icon until the fault condition is corrected NOTE Ignoring active fault codes could result in severe engine damage SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT PAGE 26 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Shut Down Codes 5 Touching the Enter Button once again will hide the fault and return the screen to the single or four parameter 1 During normal operation the single or four parameter display screen will be displayed 1800 RPM easi COOL TEMP 6 Single or Four parameter screen will display the fault icon until the fault condition is corrected NOTE Ignoring active fault codes could result in severe engine damage 2 When the diagnostic display receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the Shutdown message 3 acknowledge and Hide the fault and return to the single or four parameter display touch the Enter Button Backlight Adjustment 1 Starting at the single or four engine parameter display touch the Menu Button 4 The display will return to the single or four parameter display but the display will contain the Shut Down icon Touching the Enter Button will redisplay the hidden fault 2 The main
33. in speed ranges above maximum allowable NOTICE This generator other property or the surrounding environment could be damaged if you do not follow instructions CAUTION RESPIRATORY HAZARDS ALWAYS wear approved respiratory protection A CAUTION SIGHT AND HEARING HAZARDS 2m T On a ALWAYS wear approved eye and hearing protection AX CAUTION EQUIPMENT DAMAGE MESSAGES Other important messages are provided throughout this manual to help prevent damage to your generator other property or the surrounding environment DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 9 DCA 220SSJ SSJU RULES FOR SAFE OPERATION AX DANGER READTHIS MANUAL Failure to follow instructions in this manual may lead to serious injury or even DEATH This equipment is to be operated by trained and qualified personnel only This equipment 1 for industrial use only The following safety guidelines should always be used when Generator General Safety 2 DO NOT operate or service this manual The operator MUST BE familiar with proper safety precautions and operations techniques before using This equipment should not be operated by persons under 18 years of age NEVER operate this equipment without proper protective protective devices required by the job NEVER operate this equipment when not medicine NEVER operate this equipment under the inf
34. is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 F If the specific gravity should fall to 1 245 or lower it indicates that the battery is dead and needs to be recharged or replaced Before charging the battery with an external electric source be sure to disconnect the battery cables Battery Cable Installation ALWAYS be sure the battery cables Figure 37 are properly connected to the battery terminals as shown below The Red Cable is connected to the positive terminal of the battery and the Black Cable is connected to the negative terminal of the battery A CAUTION BATTERY SERVICING SAFETY ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 37 Battery Connections When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL or AUTO position ALWAYS make sure that the MPEC Control Switch is in the OFF RESET position when connecting the battery Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals NO NOTICE If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery
35. menu will pop up on the display Use the Arrow Buttons to scroll through the menu until the Adjust Backlight is highlighted GO TO 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS 4 a ADJUST BACKLIGHT Qe OCAQ DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 27 DCA 220SSu SSJU DIAGNOSTIC DISPLAY 3 6 Once the Adjust Backlight menu item has been highlighted touch the Enter Button to activate the Adjust Backlight function Use the Arrow Buttons to select the desired backlight intensity Touch the Menu Button to exit the Main menu and return to the engine parameter display SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT N Contrast Adjustment Starting at the single or four engine parameter display touch the Menu Button The main menu will pop up on the display Use the Arrow Buttons to scroll through the menu until Adjust Contrast is highlighted STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Once the Adjust Contrast menu item has been highlighted touch the Enter Button to activate the Adjust Contrast function STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAS Use the Arrow Buttons to select the desired contrast intensity 6
36. running the generator in the AUTO mode remember the generator can start up at any time without warning NEVER attempt to perform any maintenance when the generator is in the auto mode A CAUTION ENGINE SPEED SWITCH The Engine Speed Switch must be set to the High position when running in the Auto Start mode Failing to setthe switch in the proper position can result in damage to your generator when it turns on NOTICE When the MPEC control switch is placed in the AUTO position the engine glow plugs will be warmed and the engine will start automatically When starting generator in AUTO mode use the Manual Start up procedure except where noted see below Perform steps 1 through 6 in the Before Starting section as outlined in the Manual Starting Procedure Place the engine speed switch Figure 54 in the HIGH position 4 HIGH UP Figure 54 Engine Speed Switch High Place the MPEC Control Switch Figure 55 in the AUTO position AUTO MANUAL OFF RESET Figure 55 MPEC Control Switch AUTO Continue operating the generator as s outlined in the Manual Start up procedure start at step 5 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 55 DCA 220SSJ SSJU GENERATOR SHUT DOWN PROCEDURES 51 Emergency Shutdown Procedure 1 To shut down the engine in the event of an emergency NEVER stop the engine suddenly except in
37. state safety towing regulations in addition to meeting Department of Transportation DOT Safety Towing Regulations before towing your generator ALWAYS shutdown engine before transporting Tighten both fuel tank caps securely f generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws Follow the listed Towing amp Transporting Safety guidelines for basic towing techniques Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi cold Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain ALWAYS attach trailer s safety chains to towing vehicle properly ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly DOT Requirements include the following Connect and test electric brake operation Secure portable power cables in cable tray with tie Wraps The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of
38. terrain Place chock blocks underneath wheel to prevent rolling while parked Use the trailers swivel jack to adjust the trailer height to a level position while parked Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when transporting The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of terrain Place support blocks underneath the trailers bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank Emergencies ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest and first aid kit ALWAYS know the location of the nearest phone or keep a phone on FIRST AID KIT the job site in case of emergencies ALWAYS have easy access to the phone numbers of the nearest Ambulance Doctor and Fire Department This information will be invaluable in the case of an emergency rA fimm DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 13 DCA 220SSu SSJU GENERATOR DEC
39. voltage change over board is jumpered different positions that provide 6 different output voltages at for 240V operation as shown in Figure 21 the UVWO output terminals The generator is shipped from the factory in the 240V configuration The voltage regulator VR allows the user to increase or decrease the selected voltage 30 240 UVWO Terminal Output Voltages 1 Jumper the voltage change over board for 240V operation as shown in Figure 21 Figure 23 Voltage Regulator Knob 2 Connect the load wires to the UVWO terminals as shown in Figure 24 JUMPER 6 PLACES GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 240 VAC LOAD CONNECTIONS Figure 24 UVWO Terminal Lugs 10 240V Connections Figure 21 Voltage Change Over Board 240V Configuration 10 139V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 240V operation as shown in Figure 21 2 Connectthe load wires to the UVWO terminals as shown in Figure 25 2 Connectthe load wires to the UVWO terminals as shown in Figure 22 GROUND CONNECTION MUST BE USED THREE PHASE AT ALL TIMES 240 VAC LOAD CONNECTIONS GROUND Figure 22 UVWO Terminal Lugs MUST BE USED 30 240V Connections SINGLE PHASE TIMES 3 Turnthe voltage regulator knob Figure 23 clockwise to m increase voltage output turn counterclockwise to Figure 25 UVWO Terminal Lugs decrease voltage output Use voltage regulator 10 139V Conn
40. 00 Hrs 1000 Hrs Check Engine Fwa Lewes EX Oreck Ar TK Onek Batey acate I x po Check Fan Bet Condon ukwrimis Check for Loosening of Pars Replace Engine land ertt PEK T mewnate L L L EO I TT GENERATOR 1 Replace engine oil anf filter at 100 hours first time only 2 Add Supplemental Coolant Addatives SCA S to recharge the engine coolant 3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm 25 in 4 If blowby hose needs to be replaced ensure that the slope of the bloby hose is at least a 1 2 inch per foot with no sags or dips that could collect moisture and or oil General Inspection Prior to each use the generator should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel oil and coolant leaks Use Table 14 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual Air Cleaner Every 250 hours Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Ai
41. 0016908020 0027103015 0041203000 0030003000 DCA220SSu SSJU CONTROL BOX ASSY CONT PART NAME PIER DEAD uuu u u u a u MACHINE SCREW BRACKET RESISTOR UNIT HEX HEAD BOLT RESISTOR UNIT MACHINE SCREW FUSE HOLDER 3P FUSE RIGHT SIDE 20 FUSE CENTER 10A MACHINE SCREW TERMINAL BLOCK MACHINE SCREW CONTROL PANEL STOPPER CONTROL PANEL STOPPER WASHER FLAT SNAP PIN CONTROL BOX COVER HEX HEAD BOLT CONTROL BOX BACK PANEL HEX HEAD BOLT READ BOLT AEX READ I u NUT HEX HEAD BOLT HEX HEAD BOLT MACHINE SCREW DRAIN WASHER HEAD BOLT QTY REMARKS REPLACES P N 0601827656 REPLACES P N 0601823109 REPLACES P N 0601824400 2 REPLACES P N 0601823240 2 1 2 1 P REPLACES P N 0030006000 1 1 1 1 2 1 2 UNAM DCA220SSu DCA220SSJU 1 1 1 8 1 8 DCA220SSu DCA220SSJU DCA220SSu ee DCA220SSJU m DCA220SSu DCA220SSJU 3 8 DCA220SSJU DCA220SSJU DCA220SSJU DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 81 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY 64 65 6968 66 67 70 VIEW Z 5 81 44 4 39 93 38 V A ELM j ie ee LL
42. 02 28 14 PAGE 71 DCA220SSJ SSJU GENERATOR ASSY PAGE 72 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 7 2 7 7 4 7 5 7 6 7 7 1 84 7 9 7 10 7 11 7 12 0 C1110000102 0601842334 0601823282 0018205020 0040005000 0041205000 8171070002 8171611003 C1164200004 8171015003 0012116045 0042616000 0601000209 C1112500004 0071906314 C1163400003 M4163400003 0343206120 0043606000 0012112040 0042512000 C1130100103 0226100420 8171323004 0223300120 8171323103 0221200300 0010110035 0041210000 1132200003 0226000510 0225000470 0017106016 0601850144 C1154000002 C1138000003 DCA220SSJ SSJU GENERATOR ASSY QTY REMARKS PART NAME ROTOR ASSEMBLY FIELD ASSEMBLY RESISTOR 80W 100K OHM RECTIFIER RM50TC 24 HEX SOCKET HEAD CAP SCREW WASHER LOCK WASHER FLAT FAN COUPLING DISK WASHER COUPLING HUB BALANCING 1 cO INCLUDES ITEMS W WHEN REPLACING ITEM 1 8 PURCHASE ITEM 1 11 AS SET HEX HEAD BOLT WASHER LOCK BALANCING WEIGHT KIT BEARING FLANGE BEARING 6314DDU C3 COUPLING RING COUPLING RING HEX HEAD BOLT SPRING WSHER HEX HEAD BOLT WASHER LOCK STATOR ASSEMBLY RUBBER SEAL CLAMPER RUBBER SEAL CLAMPER RUBBER SEAL
43. 04 WASHER M9116100004 WASHER 0019208020 HEX HEAD BOLT 0845031504 BLIND PLUG 0600800320 MANUAL PAK 0027106016 MACHINE SCREW 0021806016 MACHINE SCREW M4463100202 ROOF PANEL M4493501003 ACOUSTIC SHEET M3310600004 COVER 0019208020 HEX HEAD BOLT DCA220SSJ SSJU DCA220SSJU ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8 RED 4 SUNBELT GREEN 9 DESERT TAN 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED ENCLOSURE ASSY CONT QTY REMARKS 4 4 8 4 DCA220SSJ 4 DOA220SSJU 4 4 8 1 4 DCA220SSJ OQ 4 DOA220SSJU 1 1 1 1 11 10 1 1 m 8 22055 E 8 DCA220SSJU 8 1 4 4 2 2 2 3 2 1 4 22055 4 DCA220SSJU DCA220SSJ THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING A PAINTED PANEL OF A DIFFERENT COLOR MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 101 DCA220SSu SSJU ENCLOSURE ASSY PAGE 102 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1
44. 05015 0027105016 4236100604 4236400304 0019206015 0016906016 0027104016 DCA220SSJ SSJU OUTPUT TERMINAL ASSY CONT PART NAME GROMMET CIRCUIT BREAKER 1P 20A CIRCUIT BREAKER 2P 50A BRACKET CIRCUIT BREAKER BRACKET CIRCUIT BREAKER RUBBER CUSHION HEX HEAD BOLT uu HEX HEAD BOLT RECEPTACLE GF 530EM 20A RECEPTACLE CS6369 50A RECEPTACLE CS6369 50A MACHINE SCREW MACHINE SCREW HEX NUT COVER HEX HEAD BOLT HEX HEAD BOLT TERMINAL COVER HEX HEAD BOLT WASHER FLAT STAY RUBBER SIAYHDBBER u uuu HEX NUT STAY HEX HEAD BOLT HEX HEAD BOLT COVER BRACKET HEAD BOLT HEAD BOLT MACHINE SCREW DCA220SSJU ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN THE SERIAL NUMBER MAY BE REQUIRED QTY REMARKS 1 sus 2 DCA220SSJ 2 DCA220SSJU 2 3 1 1 1 2 DCA220SSJ 2 DCA220SSJU 2 3 DCA22088J
45. 20SSJU STRIPE P nsu DCA220SSJ STRIPE DCA220SSJU STRIPE DCA220SSJ STRIPE a DCA220SSJU STRIPE 2 DCA220SSJ STRIPE D eds DCA220SSJU STRIPE DCA220SSJ STRIPE DCA220SSJU STRIPE gen DCA220SSJ STRIPE eee DCA220SSJU DECAL DANGER EXHAUST GAS INDOOR DCA220SSJU 90320010 DECAL CAUTION eet M35000220 DCA220SSJU DECAL DOCUMENT BOX LOCATED pmo M91000010 DCA220SSJU DECAL WARNING START FIRES S N 8010246 1 M90420000 DCA220SSJU DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 111 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when a signed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subject to the following provisions 1 A Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain a Return Material Authoriza
46. 26 M4923200044 INTERCOOLER 1 27 M4310201304 BRACKET INTER COOLER 1 27 4493601604 ACOUSTIC SHEET 1 28 M4310201404 BRACKET INTER COOLER 1 28A M4493601604 ACOUSTIC SHEET 1 29 0010110040 HEX HEAD 4 DCA220SSu 29 0017110050 HEX HEAD 4 DCA220SSJU 29A 0030010000 ge 4 DCA220SSu 29A 0207010000 4 DCA220SSJU 29B 0040010000 WASHER LOCK uuu u 4 DCA220SSu 29C 0041210000 WASHER FLAT DCA220SSu 30 0016910025 HEX HEAD 4 DCA220SSJ 30 0016908020 HEX HEAD zT DCA220SSJU 31 M4310301103 FAN SHROUD 1 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 83 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY 64 65 6968 66 67 70 VIEW Z 5 4 27 88 422 43 33 93 58 ida L ia 45 up 4 PAGE 84 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU ENGINE AND RADIATOR ASSY NO PART NO PART NAME QTY REMARKS 32 M4310301203 FAN SHROUD 32A 4493601204 SREE T uu uman dd destinate DCA220SSu 33 0016908020 HEX HEAD BOLT 34 0016908020 HEX HEAD BOLT 35 M4310300903 FAN GUARD 36 M4310301003 FAN GUARD 37 0016908020 HEX HEAD BOLT 1 38 M4310300403 FAN GUARD 39 0016908020 HEX HEA
47. 42 Touching the Menu Button will take you back through the menus PAGE 28 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Select Units 1 Starting at the single or four engine parameter display touch the Menu Button 14 TT V 2 Themain menu will pop up on the display Use the arrow buttons to scroll through the menu until the Select Units is highlighted GO TO 1 UP DISPLAY STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 3 Once the Select Units menu item has been highlighted touch the Enter Button to access the Select Units function GO TO 1 UP DISPLAY STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 4 Use the arrows to highlight the desired units English for imperial units i e PSI F or Metric kPa Metric Bar for IS units i e kPa Bar ESPANOL FRANCAIS DEUTSCH amp 9 Q 9 6 f Touch the Enter Button to select the highlighted units gt ENGLISH METRIC KPA METRIC BAR ENGLISH METRIC KPA METRIC BAR Touch the Menu Button to exit the Main menu and return to the engine parameter display SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Setup 1 Up Display 1 Starting the single engine parameter di
48. 9 CN c t e lt Sa ae O DCA220SSJ SSJU OUTPUT TERMINAL ASSY PART NO PART NAME QTY REMARKS 4230700003 TERMINAL BOARD uuu u u u Fenai DCA220SSu 4230700113 fissi NO i pem DCA220SSJU M9220100304 OUTPUT TERMINAL BOLT 8 0801830804 OULD e DCA220SSu M9220100404 ME OU DCA220SSJU 0039316000 HEX NUT 16 0040016000 WASHER LOCK 24 0041416000 WASHER FLAT 32 3461860504 TERMINAL PLATE eee DCA220SSu M4233200004 TERMINAL o TA DCA220SSJU 0019208040 HEX BOLT DCA220SSu 0016908040 FEX HEAD POLLS u DCA220SSJU 4236100403 TERMINAL COVER 1 4236100504 OUTPUT WINDOW 1 0605010040 HINGE 2 0027103010 MACHINE SCREW 4 0030003000 4 0041203000 WASHER FLAT 4 0027103015 MACHINE SCREW 4 0030003000 NUT 4 M9220100804 SET SCREW 2 0040006000 WASHER LOCK 2 0042806000 isis DCA220SSu 0041206000 WASBEHR C omn DCA220SSJU 0080200005 RETAINING RING 2 0019206015 HEX HEAD BOLT uuu usnu u u DCA220SSu 0019206016 unun as DCA220SSJU 4236400004 OUTLET CABLE COVER 1 4236400104 OUTLET CABLE COVER SUPPORTER 1 0019206015 PIERO BOL u IRURE D
49. ALS DCA 220SSu SSJU generator is equipped with a number of safety decals Figures 2 amp 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 these decals become unreadable replacements can be obtained from your dealer OPERATING PROCEDURES Manual Starting 1 Check the engine oil coolant and fuel levels Replenish if necessary 2 Place all Circuit Breakers in the OFF position and close all 3 Check that the select the Voltage change over board is present at desired v In case of generator having multiple eae oun 4 Set the Engine speed switch to the LOW positi 5 Turn the Auto OffiReset Manual switch to the Maal position to start the engine If the engine fails to start in the specified number of attempts the overcrank lamp will indicate and the Auto OffiReset Manual switch must be returned to the OfffReset position before preceding 6 When the engine is ready for starting during cold weather operating conditions push the Intake heater button for approximately 30 seconds Start engine using the Auto OffiReset Manual switch to the Manual position As soon as the engine starts release the button If the engine still does not start utilize the water heater until water is warm If additional water heater is supplied 7 After s
50. ATER HEATER 120 VAC INPUT RECEPTACLE REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD Figure 59 DCA 220SSJ SSJUBattery Charger amp Jacket Water Heater Power Connections DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 59 DCA 220SSJ SSJU MAINTENANCE TRAILER 8 Trailer Maintenance This section is intended to provide the user with generic trailer service and maintenance information The service and maintenance guidelines referenced in this section refer to a wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment The definitions below describe some of the major components of a typical trailer that would be used with the DCA 220SSJ SSJU Whisperwatt Generator 1 Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty when trans porting equipment Braking System System employed in stopping the trailer Typical braking systems are electric surge hy draulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry in cluding the fuel cell empty Frame Length Measurement is from the ball hitch to the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement
51. BLE FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR I CONNECTOR LEFT TAIL LIGHT 1 Figure 63 Trailer Towing Vehicle Wiring Diagram PAGE 64 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU GENERATOR WIRING DIAGRAM CONTROL BOX CONTROL PANEL ia x Chargin En 6 i gei Diagram L Ld LEE LER CN4 AVR CONNECTOR VIEW FROM INSERTING WIRE SIDE Voltage Change Over Board 240V Set a lt uj p Q R n CN3 AA M AAA Avon I I 130 7 OC U VW I AVR he a ibi 3 VR EN 4 IR d V n Y C ExAT CONNECTOR VIEW FROM INSERTING WIRE SIDE Voltage Change Over Board 480V Set Figure 64 Generator Wiring Diagram DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 65 DCA 220SSJ SSJU ENGINE WIRING DIAGRAM Figure 65 Engine Wiring Diagram Lil AUX POWER AM EMBROBHCY STOP 4 ar Tie H Pe gt s 9 E D U w x a ww m DIAGNOS ECTOR viri LAM EIRLUG SIDED LAMP SIDE oracrosric GA POWER
52. D BOLT 40 M4310500803 RADIATOR HOSE UPPER 41 M4310500903 RADIATOR HOSE LOWER 42 0605515143 HOSE BAND u u Z DCA220SSu 42 0605515178 e DCA220SSJU 43 0605515142 BAND Ree mam res eet DCA220SSu 43 0605515199 HR DCA220SSJU 44 M4310401004 INTER COOLER PIPE 45 M4310501303 INTER COOLER HOSE 46 M4310501003 INTER COOLER HOSE 47 M4310501403 INTER COOLER HOSE 48 0605515207 HOSE BAND 49 0605515208 HOSE BAND 50 0605515209 HOSE BAND 51 M4310600404 BRACKET INTER COOLER PIPE 52 0016908020 HEX HEAD BOLT 53 0602326063 U BOLT 54 0602046538 PILOLEANER Dc teen DCA220SSu 54 0602046586 AIR GLEANER uu llu aa DCA220SSJU 54 0602046617 54 0602046682 OUTER ELEMENT AIR CLEANER OUTER ELEMENT AIR CLEANER P812363 DCA220SSJ 537876 DCA220SSJU 54B 0602046618 INNER ELEMENT AIR CLEANER 1 P838813 DCA220SSJ 54B 0602046683 INNER ELEMENT AIR CLEANER 1 537877 DCA22088JU 55 0602040690 INDICATOR AIR CLEANER 1 DCA220SSu 55 0602040650 INDICATOR AIR CLEANER 1 DCA220SSJU 56 0602040559 BAND AIR CLEANER 2 DCA220SSJ 56 0602040558 BAND AIR CLEANER 2 DCA220SSJU 57 0016908020 HEX HEAD BOLT 08 0207008000 HEX NUT 59 4373200304
53. ECTIONS NOTICE ALWAYS make sure that the connections to the UVWO Figure 29 UVWO Terminal Lugs Maa 10 277V Connections terminals are secure and tight The possibility of arcing exists that could cause a fire DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 47 DCA 220SSJ SSJU SETUP Circuit Breakers To protect the generator from an overload a 3 pole 600 amp main circuit breaker is provided to protect the U V and W Output Terminals overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to the OFF 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 oil level is maintained between the two notches Figure 30 on the dipstick See Table 9 for proper selection of engine oil ADD FULL LIMIT Figure 30 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is clean If the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined in the John Deere Engine Owner s Manual Oil should be warm before draining Other types o
54. ERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN 5 BLACK THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING 6 CATERPILLAR YELLOW A PAINTED PANEL OF A DIFFERENT COLOR 7 CATO GOLD ein MQW WHITE 9 DESERT TAN Uber THE SERIAL NUMBER MAY BE REQUIRED THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 99 DCA220SSJ SSJU ENCLOSURE ASSY PAGE 100 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 0 PART 0030014000 0040014000 WASHER LOCK 0041214000 WASHER FLAT 0010120045 MEX HEAD BOLT uuu u EPUM 0010120050 HEX HEAD BOLT 0030020000 HEX NUT 0040020000 WASHER LOCK 0041220000 WASHER FLAT 4443000102 4493301904 ACOUSTIC SHEET 0019210035 HEX HEAD u uu Hen 0016910025 HEX HEAD BOLT M4443300204 COVER REAR FRAME M4493302004 ACOUSTIC SHEET M4443300303 DUCT M4493302104 ACOUSTIC SHEET 0207008000 HEX NUT 0019208020 HEX HEAD BOLT 4443200403 DOOR REAR FRAME 4443600004 WINDOW PLATE 0207306000 0037906000 IU 0041206000 WASHER FLAT B9114000002 DOOR HANDLE 0021806016 MACHINE SCREW 0030006000 HEX NUT M9110100204 HINGE 08450450
55. ERMINAL TERMINAL HARD WIRE HOOKUP PANEL BLACK RED BLUE WHITE GREEN CIRCUIT BREAKERS FOR GFCI RECEPTACLES CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES 2 a RECEPTACLE ACCESS DOOR LIFT TO OPEN CIRCUIT BREAKER PANEL 5 6369 TWIST LOCK AUX POWER RECEPTACLES 120 240V 50 AMPS Figure 9 Output Terminal Panel PAGE 40 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU OUTPUT TERMINAL PANEL FAMILIARIZATION 100 VAC Receptacles There are two 120 VAC 20 amp GFCI Duplex Nema 5 20R recepacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position Each receptacle is protected by a 20 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current of both GFCI receptacles is dependent on the load requirements of the U V and W output terminal lugs Pressing the reset button resets the GFCI receptacle after being tripped Pressing the Test Button See Figure 10 in the center of the receptacle will check the function Both receptacles should be tested at least once a month 100 VAC G F C I RECEPTACLE RESET BUTTON TEST BUTTON Figure 10 G F C l Receptacle Twist Lock Dual Voltage 120 240 VAC Receptacles There are three 240 139V 50 amp auxilliary twist lock CS 6369 recepac
56. ESPANOL FRANCAIS DEUTSCH 3 Now that you have selected the language touch the Menu button to return to the main menu display Stored Fault Codes 1 Starting at the single or the four engine parameter display touch the Menu button 2 menu will pop up on the display Use the Arrow Buttons to scroll through the menu until the Stored Fault Codes is highlighted 3 Once the Stored Fault Codes menu item has been highlighted touch the Enter Button to view the Stored Fault Codes when applicable consult engine or transmission manufacturer for SAE J1939 supported parameters PAGE 22 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 B If the word MORE appears above the Arrow Buttons there are more stored fault codes that may be viewed Use the Arrow Buttons to scroll to the next Stored Diagnostic Code SPN110 FMI10 HIGH COOLANT TEMP Touch the Menu Button to exit the Main menu and return to the engine parameter display SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Engine Configuration Data 1 Starting at the single or four engine parameter display touch the Menu Button 1800 RPM easi COOL TEMP DCA 220SSu SSJU DIAGNOSTIC DISPLAY First Time Start Up 1 When power is first applied to the diagnostic display the Logo is displayed The Wait to Start message wil
57. Fax 310 637 3284 Contact multiquip com Service Department Warranty Department 800 421 1244 Fax 310 537 4259 800 421 1244 Fax 310 943 2249 310 537 3700 310 537 3700 Technical Assistance 800 478 1244 Fax 310 943 2238 CANADA UNITED KINGDOM Multiquip Multiquip UK Limited Head Office 4110 Industriel Boul Tel 450 625 2244 Unit 2 Northpoint Industrial Estate Tel 0161 339 2223 Laval Quebec Canada H7L 6V3 Tel 877 963 4411 Globe Lane Fax 0161 339 3226 Contact jmartin multiquip com Fax 450 625 8664 Dukinfield Cheshire SK16 4UJ Contact sales 9 multiquip co uk COPYRIGHT 2014 MULTIQUIP INC Multiquip Inc the MQ logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any ob
58. GINE OPERATING PANEL 8 10 11 12 13 14 Engine Speed Switch This switch controls the speed of the engine low high Pre Heat Lamp When lit indicates engine is in the pre heating mode for starting during cold weather operating conditions When lamp goes off engine is ready for starting Warning Lamp This lamp will illuminate when a critical engine fault has occured Emergency Stop Lamp This lamp will illuminate when the emergency stop button has been pressed or a critical engine fault has occured Emergency Stop Button In the event of an emergency press this button to shutdown the generator Diagnostic Display This display monitors crtical engine functions If any abnormal conditions occur an Active Fault Code will be displayed This diagnostic display can be located inside the control box Auto On Off Engine Controller MPEC This controller has a vertical row of status LED s inset that when lit indicate that an engine malfunction fault has been detected When a fault has been detected the engine auto controller will evaluate the fault ipo and all major faults will shutdown the generator During cranking cycle The MPEC will attempt to crank the engine for 10 seconds before disengaging LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING If the engine does not engage start by the third attempt the engin
59. HEX HEAD BOLT WASHER FLAT COVER RUBBER SEAL RUBBER SEAL HEX HEAD BOLT GROMMET END BRACKET FIELD ASSEMBLY EXCITER SS oo DCA220SSJ I DCA220SSJU INCLUDES ITEMS W DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 73 DCA220SSJ SSJU GENERATOR ASSY CONT PAGE 74 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PART NO 0012110065 0042610000 0041210000 0017112045 C1154400004 C1154300004 0010106060 0040006000 0041206000 C1154400103 0017106016 0343205150 0043605000 C1132300114 0010106030 0041206000 0600815000 0605000012 0030020000 0040020000 0070506307 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 75 DCA220SSJ SSJU GENERATOR ASSY CONT PART NAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX HEAD BOLT COVER BEARING GASKET BEARING HEX HEAD BOLT WASHER LOCK WASHER FLAT SUCTION COVER HEX HEAD BOLT HEX HEAD BOLT WASHER LOCK COVER FAN HEX HEAD BOLT WASHER FLAT NUT RUBBER SUSPENSION HEX NUT WASHER LOCK BEARING 6907ZZ h AMPH DORA QTY REMARKS DCA220SSJ SSJU CONTROL PANEL ASSY PAGE 76 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU CONTRO
60. John Deere Engine Manual for details To restart after running out of fuel turn the switch to the ON position for 15 30 seconds Try again if needed This unit is equipped with an automatic air bleeding system Check Oil Level Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 31 Replacing Oil Filter e Remove the old oil filter e Apply a film of oil to the gasket on the new oil filter e Install the new oil filter After the oil cartridge has been replaced the engine oil will drop slightly Run the engine for a while and check for leaks before adding more oil if needed Clean excessive oil from engine Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water Remove dust or water in the strainer cap and wash it in gasoline Securely fasten the fuel strainer cap so that fuel will not leak Check the fuel strainer every 200 hours of operation or once a month Replacing Fuel Filter e Replace the fuel filter cartridge with new one every 500 hours so e Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed water DO NOT spill the fuel during disassembly e Vent any air Flushing Out Radiator and Replacing Coolant Open
61. L PANEL ASSY O PART NO M4223000303 4223000404 0222100100 0222100165 0605011211 0016908035 0017108040 0601807642 0601808992 0601801040 0601800275 0601801041 10 0601840073 11 0601840121 12 0602202593 13 0027104035 13 0021004040 13A 0207004000 14 0601831340 15 0601831395 16 0602120096 17 0602122093 18 0602122272 19 0602123092 20 0602123263 21 0602121081 22 0602125090 23 0602103092 23A 0601810245 24 0601810160 24A 0601810213 20 0207004000 26 0601831330 27 0601831557 28 M9220100004 28A 0080200007 29 M4246700304 30 M4357200102 30 M4357200112 x PART NAME CONTROL PANEL CONTROL PANEL RUBBER SEAL RUBBER SEAL PIN HEAD BOLT uu u ite HPEADIOL LIS FREQUENCY METER 45 65HZ 240V AC AMMETER 0 400A 0 800A CHANGE OVER SWITCH AMMETER AC VOLTMETER 0 600V CHANGE OVER SWITCH VOLTMETER RHEOSTAT VR 2W 1K OHM Q KNOB CONTROLLER ECU MACHINE SCREW MACHINE SCREW NUT SWITCH ENGINE SPEED SWITCH TACHOMETER OIL PRESSURE GAUGE OIL PRESSURE UNIT WATER TEMPERATURE GAUGE WATER TEMPERATURE UNIT CHARGING AMMETER FUEL GAUGE ALARM LAMP BULB DC 18V PANEL LIGHT DC 12V BULB HEX NUT PANEL LIGHT SWITCH EMERGENCY STOP BUTTON SET SCREW SNAP RING WIRE HARNESS GENERATOR WIRE HARNESS ENGINE WIRE HARNESS ENGINE
62. NE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL T ST ENGINE OIL PRESSUR 15 Touch the Menu Button to exit the Main menu and return to the engine parameter display Touch the Enter Button to change the selected parameter in the quadrant to the new parameter GO TO DISPLAY ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ENGINE SPEED 3 ENGINE HOURS ENGINE TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL RE ENGINE OIL PRESSURE Utilities information and troubleshooting 1 Starting at the single or four engine parameter display Use the Menu Button to return to the 4 Up Custom touch the Menu Button Setup screen M 2 ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE 1 BATTERY POTENTIAL ENGINE OIL TEMPERATURE ENGINE OIL PRESSURE 2 The main menu will be displayed Use the Arrow Buttons The parameter in the selected quadrant has changed to scroll through the menu until the Utilities is to the parameter selected in the previous screen highlighted STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 3 Once the Utilities menu item has been highlighted touch the Enter Button to activate the Utilities functions Repeat the parameter selection process until all spaces are filled STORED CODES ENGINE CONFG SETUP 1 UP DIS
63. NOT effect the generator output They are provided to help observe how much power is being supplied produced at the UVWO terminals lugs When the voltage change over board Figure 16 is jumpered for 30 240V operation place the AC Voltmeter Change Over Switch Figure 17 to the W U position and the AC Ammeter Change Over Switch Figure 19 to the U or W position Use the AC voltmeter or AC ammeter Figures 18 and 20 to read the output on the selected leg of the UVWO terminals V W U V OFF Figure 17 AC Voltmeter Figure 18 AC Voltmeter Gauge Change Over Switch Volt reading on W U Lug V U W OFF Figure 20 AC Ammeter Amp reading on U lug Figure 19 AC Ammeter Change Over Switch NOTICE The ammeter gauge will only show a reading when the output terminal lugs are connected to a load and in use DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 45 DCA 220SSJ SSJU OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages DECREASE INCREASE Various output voltages can be obtained using the UVWO output terminal lugs The voltages at the terminals are de pendent on the placement of the jumpers plates 6 on the Voltage Change Over Board and the adjustment of the Voltage Regulator Control Knob Remember the voltage change over board determines the 10 240 UVWO Terminal Output Voltages range of the output voltage and can be configured in two 1 Make sure the
64. OPERATION AND PARTS MANUAL MULTIQUIP 27 POWER MODEL DCA220SSJ SSJU 60HZ WHISPERWATT GENERATOR JOHN DEERE 6068HF485 DIESEL ENGINE PARTS LIST NO C1870300404 DCA220SSJ PARTS LIST NO M4870300104B DCA220SSJU Revision 1 02 28 14 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES DCA 220SSJ SSJU PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU NOTE PAGE DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE DCA 220SSJ SSJU TABLE OF CONTENTS MQ POWER DCA 220SSJ SSJU WHISPERWATT GENERATOR California Proposition 65 Warning 2 Table Of Contei nenioman 4 Parts Ordering Procedures 5 PENCON MINI Ossa 6 Dimensions Top Side 7 Safety Message Alert 8 9 Rules for Safe Operation 10 13 Generator 14 15 l bi E 16 17 Generalinio u IR 18 Major Components T 19 Diagnostic Display 20 36 Gene
65. PLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 33 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Touch Select to enter the Gage Data display When Gage Data is selected the PowerView will communicate with the analog gages at a fixed rate of 38 4k Band 8 data bits no parity check 1 stop bits half duplex REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION ADJUST BACKLIGHT DEMO MODE ON Use the Arrow Buttons to scroll through the items or touch Menu to return to the Utilities menu ENGINE OIL PRESSURE ADDRESS 20 SOFTWARE REVISION ERRORS NONE ENGINE OIL PRESSURE ADDRESS 20 SOFTWARE REVISION ERRORS NONE Use the Arrows to highlight Remove All Gages Touch Select to clear gage data from memory It takes a moment to clear all gages CLEARING GAGES PLEASE WAIT Q 8 When the gage data has cleared the display automatically returns to the Utilities menu Scroll to Software Version Touch Select to view the software version currently in the diagnostic display 9 Touch Menu to return to Utilities Highlight Fault Conversion using the Arrows Touch Select to enter the Fault conversion menu GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION FAULT CONVERSION 10 Use the Arrows to scroll to and highlight the desired version then
66. QTY D G HS SS PB N REMARKS DCA220SSJ DCA220SSJU DCA220SSu DCA220SSJU S N 8010001 8010165 S N 8010166 AND ABOVE DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 77 DCA220SSJ SSJU CONTROL BOX ASSY PAGE 78 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU CONTROL BOX ASSY NO PART NO PART NAME QTY REMARKS 1 4213000102 CONTROL BOX 1 2 0601809667 CURRENT TRANSFORMER 400 5A 3 3 0027106016 MACHINE SCREW 6 4 0601870422 CIRCUIT BREAKER 600A 1 4A 0021006045 MACHINE SCREW DCA220SSJU 4B 0207006000 NUT e asan 4 DCA220SSJU 5 0601815168 REAR CONNECTOR KIT 1 6 M4273000003 TERMINAL BOARD VOLTAGE CHANGE OVER 1 7 M4276400004 CHANGE TERMINAL 10 8 0017106025 HEX HEAD BOLT 20 9 4276200004 TERMINAL PLATE 3 10 4276300004 CHANGE OVER PLATE 6 11 M4276100004 AINE BOLT DCA220SSu 12 M9220100104 TE BOLT s o DCA220SSu 12 M9220100104 TEBO M DCA220SSJU 13 0040010000 WASHER LOCK 26 14 0041410000 WASHER FLAT 26 15 0016908030 HEX HEAD BOLT 4 16 0601820625 AUTOMATIC VOLTAGE REGULATOR DCA220SSu 16 0601820601 AUTOMATIC VOLTAGE REG DCA220SSJU datae S N 8010001 8010165 16 0601820625 AUTOMATIC VOLTAGE REG
67. S DCA220SSu 9 C1346600104 PA TERT DL ete u ener DCA220SSu 10 EARTH CABLE DCA220SSJ4 pm MAKE LOCALLY 11 0347010003 HEX HEAD BOCI tap E cune DCA220SSu 12 0208110000 gla NO T Pee ee ee ee P ansam DCA220SSu 13 0845040414 TERMINAL CAP j DCA220SSu 14 0845041304 TERMINAL CAP DCA220SSu 15 0017116030 HEX HEAD DCA220SSu 16 0040516000 TOOTHED WASHER L uuu u DCA220SSu 17 0040520000 TOOTHED WASHER uu u u u u prem DCA220SSu 18 0602220196 sa Fe DCA220SSJU 19 M9310500404 u DCA220SSJU 20 M9103000504 x DCA220SSJU 21 0602220921 BATTERY BOLT DCA220SSJU 22 M4346900304 BATTERY OABLE uu u DCA220SSJU 23 M4346900204 BATERI eee err j DCA220SSJU 24 EARTH CABLE DCA220SSJU jp MAKE LOCALLY 25 0017116030 HEX READ BOLI DCA220SSJU 26 0040516000 TJOQIHEDWASHER u u u aaa DCA220SSJU 27 0040520000 zas DCA220SSJU DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 93 DCA220SSu SSJU MUFFLER ASSY PAGE 94 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ SSJU
68. SJ SSJU MAINTENANCE TRAILER Brakes Trailer brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles driving over rough terrain inspect the brakes more frequently Figure 59 displays the major hydraulic surge brake components that will require inspection and maintenance Please inspect these components as required using steps 1 through 8 and Table 15 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly to expand the brake shoes 5 Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6 Adjust rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 7 on the remaining brakes Hydraulic Surge Brakes Hydraulic surge brakes Figure 60 should not require any special attention with the exception of routine maintenance such as shoe and lining replaceme
69. SJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 107 DCA220SSJ SSJU NAMEPLATE AND DECALS ASSY 2 2 B 2 8 13 DAC220SSJU ONLY 2 gt 22055 ONLY J B 10 DAC220SSJU 2 6 2 5 2 4 i 2 VIEW Z PAGE 108 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 0 M4550000303 B9521100404 M9520100304 C9521100003 M9520100603 1550000102 M4550000202 0800520904 M9520000104 0800520814 M9520000204 9531100604 9520100004 M9520200404 C0551000903 M9520200303 M9522000504 C9521007504 M9520000904 6360620204 M9500000004 6360610304 M9500100004 B9504000404 M9503000004 1320610603 M9503000103 B9504100104 M9503100004 B9504000304 M9510100004 M1550000703 M4550000503 0840614104 M9520000004 9039209064 M9520000504 M9520000704 0840619904 M9520100404 M9520100503 DCA220SSJ SSJU NAMEPLATE AND DECALS ASSY PART NAME QTY REMARKS DECAL OPERATING PROCEDURES 45000030 DECAL SAFETY INSTRUCTIONS mem B92110040 22055 DECAL SAFETY INSTRUCTIONS 1 92010030 DCA220SSJU DECAL CAUTION ee C92110000 DCA220SSJ DECAL M92010060 DCA220SSJU CONTROL PANEL BOX GROUP DECAL CONTROL PANE pem C15000010 DCA220SSJ DECAL rt Errant si em 45000020 DCA220
70. SSJU PLATE CHANGE OVER SWITCH em N 2438 DCA220SSJ PLATE CHANGE OVER SWITCH a M92000010 DCA220SSJU PLATE VOLTMETER CHANGE OVER SWITCH N 2439 DCA220SSJ PLATE VOLTMETER CHANGE OVER SWITCH M92000020 DCA220SSJU DECAL WARNING ELECTRIC SHOCK HAZARD B93110060 DCA220SSJ DECAL WARNING ELECTRIC SHOCK HAZARD 92010000 DCA220SSJU DECAL OVER CURRENT RELAY M92020040 DECAL SETTING FOR OUTPUT VOLTAGE a C05100090 DCA220SSJ DECAL SETTING FOR OUTPUT VOLTAGE 92020030 DCA220SSJU DECAL CIRCUIT BREAKER 92200050 DECAL DIAGNOSTIC SWITCH mm C92100750 DCA220SSJ DECAL DIAGNOSTIC SWITCH eee M92000090 DCA220SSJU ENGINE AND RADIATOR GROUP DECAL OIL DRAIN PLUG 51885 22055 DECAL OIL DRAIN ere M90000000 DCA220SSJU DECAL WATER c M pem 91880 22055 DECAL WATER asss M90010000 DCA220SSJU DECAL WARNING MOVING PARTS D esie B90400040 DCA220SSu DECAL WARNING ROTATING PARTS D M90300000 DCA220SSJU DECAL WATER OIL CHECK asss S1760 DCA220SSJ DECAL WATER OIL CHECK usq M90300010 DCA220SSJ
71. STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Once in the Utilities menu use the Arrows to scroll through the menu until the Modbus Setup menu is highlighted then touch Enter GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION Use the Arrows to scroll down to and highlight either the Slave Active or Master Active modes Touch the Enter button to toggle between master and slave lt USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE Use the Arrows to scroll to the Serial Port menu to highlight it then touch Enter USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE Use the Arrow button to scroll to each selection to configure the MODBUS values for your application BAUD RATE PARITY DATA BITS STOP BITS When finished touch Menu to return to the previous screen DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 35 DCA 220SSu SSJU DIAGNOSTIC DISPLAY GLOSSARY Troubleshooting information CANBUS FAILURE Diagnostic Display has not received any CAN messages for at least 30 seconds NO DATA Diagnostic Display has not received the particular message being displayed for at least 5 seconds NOT SUPPORTED Diagnostic Display has received a message from the ECU stating the di
72. U DECAL WARNING HOT COOLANT B90410010 22055 DECAL WARNING HOT COOLANT a M90310000 DCA220SSJU DECAL CAUTION HOT PARTS mem B90400030 DCA220SSJ DECAL CAUTION HOT PARTS a M91010000 DCA220SSJU OUTPUTTERMINAL GROUP DECAL RECEPTACLE AND CIRCUIT BREAKER 1 15000070 DCA220SSJ DECAL RECEPTACLE AND CIRCUIT BREAKER 1 M45000050 DCA220SSJU DECAL GROUND 52635 22055 DECAL GROUND uuu qu M92000000 DCA220SSJ DECAL START S4468 DCA220SSJ DECAL START CONTACT M92000050 DCA220SSJ DECAL 3 PHASE OUTPUT TERMINAL 92000070 DECAL DANGER HIGH VOLTAGE er 92731 DCA220SSJ DECAL DANGER HIGH VOLTAGE M92010040 DCA220SSJU WABNING L M92010050 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 109 DCA220SSJ SSJU NAMEPLATE AND DECALS ASSY CONT 2 2 B 2 8 13 DAC220SSJU ONLY B 12 DAC220SSJU ONLY J i B 10 DAC220SSJU 2 6 2 5 2 4 1 2 VIEW Z PAGE 110 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSJ
73. ZARD ELECTRIC SHOCK HAZARD e Before connecting this generator to any building s electrical system a licensed electrician must install e Do not touch output Always complete the grounding an isolation transfer switch terminals when this the ground terminal ine this genset to an external source See instruction e Serious injury or death may result without this e Turn power off before manuel detil transfer switch servicing M9520 100503 P N M9520100503 WARNING HOT COOLANT can cause A WARNING severe burns x ENGINE EXHAUST can cause Do not remove cap if severe injury or death radiator is hot Use only in open well ventilated areas or vent exhaust outside P N M9503100004 P N M9503200004 DANGER A CAUTION Stop engine before switching HIGH VOLTAGE A CAUTION M9520100401 MOVING PARTS can cause severe injury gt Do not operate with doors open Stop engine before servicing M90300000 M90310000 9520100204 P N M9520100204 P N M9520100404 To use 50 amp receptacles adjust the voltage selector switch to the single phase position and the main line circuit breaker to the on position P N M1500020 P N M1550000204 A WARNING CAUTION ELECTRIC SHOCK HAZARD HOT PARTS can burn skin e Do not touch output terminals while this MW P N 9503000004 Do not touch until machine is ope
74. an emergency P aH push the Emergency Stop Button Figure 58 2 Switch the MAIN GFCI and LOAD Figure 38 circuit A CAUTION DIAGNOSTIC SWITCH breakers to OFF position ALWAYS make sure the diagnostic switch is placed in the OFF position before attempting to shut down the generator Cy The OFF RESET switch on the MEC controller will not shut down the generator if the diagnostic switch is left in the ON position Normal Shutdown Procedure Sto To shutdown the generator use the following procedure Figure 58 Emergency Stop Button 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 39 to the OFF position 2 Place the engine speed switch Figure 56 in the LOW down position E w LOW DOWN Figure 56 Engine Speed Switch Low 3 Let the engine cool by running it at low speed for 3 5 minutes with no load applied 4 Place the MPEC Control Switch Figure 57 to the OFF RESET position AUTO MANUAL OFF RESET Figure 57 MPEC Control Switch Off Reset 5 Verify that the all status LED on the MPEC display are OFF not lit Remove all loads from the generator Inspect entire generator for any damage or loosening of components that may have occured during operation PAGE 56 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU MAINTENANCE ENGINE TABLE 14 INSPECTION MAINTENANCE 10 Hrs DAILY 250 Hrs 5
75. arts immediately check for abnormal noise vibration fluid leakage any indication of a problem Check the control panel gauges If all is normal let the engine remain at the Low position for a short time depending on the ambient conditions warm ul 9 After sufficient warm up time has elapsed set the Engine speed switch to the High position and the unit is ready for operation 10 Check the speed as shown i table below 60 0Hz 180 11 Adjust the Voltage Regulator to the voltage P N M3552000103 U V OFF P N M9520000104 output terminal cover and control panel Close the cover and control panel before operating Moving parts and hot surfaces are contained within the enclosure Close all doors and lock them before operating M92010030 P N M9520100304 OIL DRAIN PLUGS M35200010 M9000000 P N M950000004 OVER CURRENT RELAY If it is Impossible to reset the CIRCUIT BREAKER open the control panel and push the RESET BUTTON as below P N 9520000204 P N M9520200104 P N 9500300104 9500300004 WATER OIL CHECK AND FILL DAILY M90300010 P N M9503000103 P N M9510200002 DIESEL FUEL P N M9500500004 Figure 2 Generator Decals PAGE 14 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU GENERATOR DECALS A WARNING WARNING A WARNING ELECTRIC SHOCK HA
76. 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 kit that can be purchased or is not available for sale through Multiquip PAGE 70 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA220SSu SSJU SUGGESTED SPARE PARTS DCA 220SSJ SSJU WHISPER WATTGENRATOR W JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS Qty P N Description 4310500803 HOSE RADIATOR UPPER M4310500903 HOSE RADIATOR LOWER pm 06020110062 RADIATOR CAP eem 0845500104 FUEL CAP DCA220SSJ LC 0605505070 FUEL CAP DCA220SSJU 02 0602015230 V BELT SET FAN em 0602122272 UNIT OIL PRESSURE 0602123263 SWITCH TEMPERATURE SENSOR 0810105400 FILTER FUEL FUEL TANK 06020425996 FILTER FUEL PRIMARY oA 0602042597 FILTER FUEL FINAL 0602041292 FILTER OIL CARTRIDGE O ranie 0602046617 ELEMENT AIR OUTER 0602046618 ELEMENT AIR INNER ieee 0601808803 CIRCUIT BREAKER 1P 20A asss 0601808804 CIRCUIT BREAKER 2P 50A LY2DUS12VDC RELAY NOTICE Part number on this Suggested Spare Parts list may supercede replace the P N shown in the text pages of this book DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1
77. cally clean the radiator fins with compressed air Cleaning inside the machine is dangerous so clean only with the engine turned off and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the John Deere Engine Owner s Manual Fan Belt Tension A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear and adjust it in accordance with the John Deere Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 36 when depressed with the thumb as shown below 10 15 MM DEFLECTION NEVER place hands near the belts or fan while the generator set is running PAGE 50 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU SETUP Battery This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level are not properly maintained Add only distilled water when replenishment is necessary DO NOT over fill Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The battery
78. cution can result from operating an ungrounded generator ALWAYS be sure to use the ground terminal green wire when connecting a load to the U V and W output terminal lugs Electrical Safety ALWAYS have a qualified electrician perform the generator wiring installation ALWAYS make sure generator installation is accordance with the National Electrical Code NEC and local codes before operating generator NEVER use a defective or frayed power cable Check the cable for cuts in the insulation NEVER use a extension cord that is frayed or damaged where the insulation has been cut ALWAYS make certain that proper extension cord has been selected for the job See Table 6 NEVER power cables or cords lay water NEVER stand in waterwhile AC power from the generator is being transfer to a load A DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH To avoid these hazards NEVER use damaged or worn cables when connecting equipment to the generator Make sure power connecting cables are securely connected to the generator s output terminals insufficient tightening of the terminal connections may cause damage to the generator and electrical shock NEVER grab or touch a live power cord with wet hands NEVER touch output terminals during operation This i
79. d display unit will operate in extreme hot or cold weather conditions Other components in the system are microprocessor based components for displaying critical engine data broadcast by an electronic engine or transmission s Engine Control Unit ECU engine RPM oil pressure coolant temperature system voltage etc and a combination audible alarm and relay unit for warning and shutdown annunciation The Engine Control Unit ECU used with this generator diagnosis engine faults that arise with the the engine control system and the engine itself Engine faults can be determined by viewing the Diagnostic Trouble Codes Active Fault Codes which are displayed on the Diagnostic Display Panel See the John Deere Engine Operators Manual for a complete listing of active fault codes and countermeasures The following definitions describe the controls and functions of the Diagnostic Display Panel Figure 6 1 Menu Button Press this button to enter or exit menu screens 2 LeftArrow Button Press this button to scroll through the screen either moving the parameter selection toward the left or upward 3 Right Arrow Button Press this button to scroll through the screen either moving the parameter selection toward the right or downward 4 Enter Key Button Press this button to select the parameter that is highlighted on the screen 5 Emergency Stop LED When lit RED indicates a major fault has occured This condition will shudo
80. e generator s output voltage 5 AC Voltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs 6 Voltmeter 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 7T Main Circuit Breaker This three pole 600A main breaker is provided to protect the the U V and W Output Terminal Lugs from overload Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the generator function The Control Box is equipped with the following major components Over Current Relay Voltage Rectifer AVR Starter Relay Current Transformer Voltage Selector Switch Three Phase Circuit Breaker NOTICE Remember the overcurrent relay monitors the current flowing from the U V and W Output Terminal Lugs to the load In the event of a short circuit or over current condition it will automatically trip the 600 amp main breaker To restore power to the Output Terminal Panel press the reset button on the overcurrent relay and place the main circuit breaker in the closed position ON DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 37 DCA 220SSJ SSJU ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA 220SSJ SSJU Engine Operat
81. e will be shutdown by the engine controllers Over Crank Protection mode If the engine engages at a speed RPM s that is not safe the controller will shutdown the engine by initializing the Over Speed Protection mode Also the engine controller will shut down the engine in the event of low oil pressure high coolant temperature low coolant level and loss of magnetic pickup These conditions can be observed by monitoring the LED status indicators on the front of the controller module A MPEC Control Switch This switch controls the running of the unit If this switch is set to the OFF RESET position the unit will not run When this switch is set to the MANUAL position the generator Will start immediately If the generator is to be connected to a building s AC power source via an automatic transfer switch isolation place the switch in the AUTO position In this position should an outage occur the automatic transfer switch ATS will start the generator 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 the auto start contacts of the generator to the ATS Low Oil Pressure Indicates the engine pressure has fallen below 15 psi The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered a major fault High Coolant Temperature
82. ections adjustment knob whenever fine tuning of the output voltage is required PAGE 46 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU OUTPUT TERMINAL PANEL CONNECTIONS 30 480 UVWO Terminal Output Voltages 10 480V UVWO Terminal Output Voltages 1 Jumperthe voltage change over board for 480V operation 1 Make sure the voltage change over board is jumpered as shown in Figure 26 This configuration uses 6 jumper for 480V operation as shown in Figure 26 plates in 3 different positions Remember there are 2 Connect the load wires to the UVWO terminals as shown jumper plates at every position Every jumper plate must in Figure 28 be used USE 2 JUMPER PLATES AT EACH POSITION GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE Figure 26 Voltage Change Over Board 480 VAC LOAD CONNECTIONS 480V Configuration Figure 28 UVWO Terminal Lugs 2 Connect the load wires to the UVWO terminals as shown in Figure 27 10 277V UVWO Terminal Output Voltages 1 sure the voltage change over board 1 jumpered for 480V operation as shown in Figure 26 2 Connect the load wires to the UVWO terminals as shown in Figure 29 GROUND CONNECTION MUST BE USED THREE PHASE AT ALL TIMES 480 VAC LOAD CONNECTIONS Figure 27 UVWO Terminal Lugs GROUND 30 480V Connections CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 277 VAC LOAD CONN
83. eed Switch Low 2 Place the MPEC Control Switch in the MANUAL position to start the engine Figure 42 Observe that the Warning and Emergency Stop lamps on the Engine Operating Panel are lit during the initial starting of the engine If no abnormal conditions exists both lamps will turn off MANUAL OFT RESE Figure 42 MPEC Control Switch Manual Position PAGE 52 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU GENERATOR START UP PROCEDURE MANUAL NOTICE 8 Torestart the engine due to error codes place the MPEC Control Switch in the MANUAL position Figure 42 When the MPEC control switch is placed in the manual position Figu position preheating of the glow plugs will begin 9 If the engine is running smoothly place the engine automatically and the preheat lamp will speed switch Figure 44 in the HIGH up position stay lit until the glow plugs are warmed When the preheat lamp goes off this signals HIGH UP the completion of the preheating cycle and 4 the starting of the engine Preheat Lamp 3 If any abnormalities exists the Warning and Figure 44 Engine Speed Switch High Emergency Stop lamps on the Engine Operating Panel will be lit 4 Place the MPEC Control Switch Figure 42 in the 10 Verify that the Engine Running auro OFF RESET position status LED on the MPEC unit Figure 45 is ON lit afte
84. emperature Gauge Oil Pressure Gauge Charging Ammeter Gauge Fuel Level Gauge Engine Speed Switch Panel Light Panel Light Switch Auto ON OFF Engine Controller MPEC Preheat Lamp Warning Lamp Emergency Stop Lamp Emergency Stop Button Generator Control Panel The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator 3 Pole 600 amp Main Circuit Breaker Control Box located behind the Gen Control Panel Automatic Voltage Regulator Diagnostic Display Current Transformer Over Current Relay Voltage Rectifer Starter Relay Engine Controller Computer Controlled Voltage Change over Board Output Terminal Panel The Output Terminal Panel is provided with the following Three 120 240V output receptacles CS 6369 50A Three auxilliary circuit breakers 50A Two 120V output receptacles GFCI 20A Two GFCI circuit breakers 20A Five output terminal lugs 30 power Battery Charger Optional Water Heater Optional Open Delta Excitation System DCA 220SSJ SSJU generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the powe
85. er Refer to dealer Wire shorted Inspect repair wire Low coolant level Fill coolant level on Optionally Installed Sending unit failure Replace sending unit Low battery voltage Replace charge battery Fan belt tension incorrect Tighten replace fan belt Air flow is not circulation through radiator Clean repair radiator grill High coolant temperture Exhaust leaking Replace repair gaskets or faulty part light is on Generator being overloaded Check reduce load Thermostat failure Replace thermostat Air intake blocked Clear all air intakes Temperature switch failure Replace temperature switch No or low Fuel Fill fuel level Overcrank light is on Controller needs to be calibrated Refer to dealer RPM engine speed too high Adjust RPM Governor actuator needs to be adjusted Adjust governor actuator Overspeed light is on Governor controller needs to be adjusted Adjust governor controller Engine Controller needs to be calibrated Refer to dealer Loss of MPU light s or Magnetic pick up out of adjustment Adjust magnetic pick up Magnetic pick dirty Clean magnetic pick up PAGE 68 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 69 DCA220SSJ SSJU EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in t
86. f motor oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD API Service Classification CC SE Service Classification CC SF Table 11 Recommended Motor Fuel Check DANGER EXPLOSION FIRE HAZARDS Fuel spillage on a hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator Refilling the Fuel System A CAUTION REFUELINGTHE GENERATOR ONLY properly trained personel who have read and understand this section should refill the fuel tank system This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank Figure 31 ALWAYS fill the fuel tanks with clean fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their Capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filling Handle fuel in a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately TRAILER MOUNTED FUEL TANK OPTION b ENVIRONMENTAL FUEL TANK OPTION Figure 31 Internal Fuel Tank System PAGE 48 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU SETUP 3
87. from the tongue of the trailer Coupler Type of hitch used on the trailer for towing 16 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten down the lug nuts See Table 16 and Figure 59 for lug nut tightening and sequence Axle Indicates the maximum weight the axle can sup port in pounds and the diameter of the axle expressed in inches Please note that some trailers have a double axle This will be shown as 2 6000 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle Application Indicates which units can be employed on a particular trailer PAGE 60 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220S
88. gnosis engine faults that arise with the the engine control system and the engine itself Engine faults can be determined by viewing the Diagnostic Trouble Codes Active Fault Codes which are displayed on the Diagnostic Display Panel located inside the Control Box 1 Before starting the engine make sure the diagnostic switch Figure 38 on the Diagnostic Display Panel Assembly is in the OFF position DIAGNOSTIC Figure 38 Diagnostic Switch OFF poistion 2 Place the main G F C l and aux circuit breakers Figure 39 in the OFF position prior to starting the engine MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 39 Main Aux and GFCI Circuit Breakers OFF 3 Make sure the the voltage change over board has been configured for the desired output voltage 4 Connect the load to the receptacles or the output terminal lugs as shown in Figure 14 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 5 The output terminal lugs are protected by a plastic cover Remove this cover to gain access to the terminals Tighten terminal nuts securely to prevent load wires from slipping out 6 Close all engine enclosure doors Figure 40 CORRECT INCORRECT Figure 40 Engine Enclosure Doors Starting Manual 1 Place the engine speed switch Figure 41 in the LOW down position w LOW DOWN Figure 41 Engine Sp
89. han during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 When connecting a resistance load such as incandescent lamp or electric heater a capacity of up to the generating set s rated output KW can be used When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output kW multiplied by 0 6 can be used When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used A DANGER ELECTRICAL SYSTEM HAZARDS Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 43 DCA 220SSu SSJUU GENERATOR OUTPUTS Generator Output Voltages A wide range of voltages are available to supply voltage for many different applications Voltages are selected by apply ing jumpers 6 to the voltage change over board Figure 15 To obtain some of the voltages as listed in Table 6 see below will require a fine adjustme
90. he Menu Button Setup 4 Up Display menu 6 Select the 4 Up Custom Setup from the 4 Up Setup 2 The main menu will pop up on the display Use the Arrow menu Buttons to scroll through the menu until the Setup 4 Up Display is highlighted USE DEFAULTS CUSTOM SETUP SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 7 The quadrant with the backlit parameter value is the current selected parameter Use the Arrow Buttons to highlight 3 Once the Setup 4 Up Display menu item has been the parameter value in the quadrant you wish to place a highlighted touch the Enter Button to activate the new parameter Setup 4 Up Display menu USE DEFAULTS CUSTOM SETUP GO TO 1 UP DISPLAY STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 4 Touch the Enter Button to activate the Use Defaults function This action will reset the unit to the factory default USE DEFAULTS CUSTOM SETUP PAGE 32 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 12 13 DCA 220SSu SSJU DIAGNOSTIC DISPLAY The parameter that is highlighted is the selected 14 Touch the Menu Button to return to the main menu parameter for the screen Use the Arrow Buttons to highlight the new parameter to be placed in the quadrant selected in the previous screen ENGINE SPEED ENGINE HOURS ENGI
91. he ON position Figure 53 MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 53 Main Aux Circuit Breakers 19 Observe the generator s ammeter Figure 54 and verify it reads the anticipated amount of current with respect to the load The ammeter will only display a current reading if load 1 in use Figure 54 Ammeter Load 20 The generator will run until manually stopped or an abnormal condition occurs Starting Auto Mode A DANGER ELECTRICAL SYSTEM HAZARDS Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch AX CAUTION BACKUP GENERATOR USE When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure that the engine will not fail due to a dead battery NOTICE When the generator is set in the AUTO mode the generator will automically startin the event of comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch PAGE 54 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU GENERATOR START UP PROCEDURE AUTO MODE A WARNING AUTO MODE MAINTENANCE When
92. he Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions NOTICE The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST NO PART PART REMARKS 1 12345 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol 8 96 or gt in the number column belong to the same assembly or kit which is indicated by a note in the Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication
93. he battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come in contact with a flame or spark an explosion could occur ALWAYS keep the battery charged If the battery is not charged a buildup of combustible gas will occur ALWAYS keep battery charging and cables in good working condition Repair or replace all worn cables ALWAYS recharge the battery in an vented air environment to avoid risk of a dangerous concentration of combustible gases n case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water Incase the battery liquid dilute sulfuric acid comes in contact with your EYES rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention PAGE 12 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU RULES FOR SAFE OPERATION Towing amp Transporting Safety To reduce the possibility of an accident while transporting the generator on public roads always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of safety precautions should be followed when towing your generator CAUTION FOLLOW TOWING REGULATIONS Check with your local county or
94. he cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 62 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 18 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 18 Tire Torque Requirements Ld d ET FT LBS FT LBS FT LBS PNEUMATIC AIR GUN TORQUE WRENCH Figure 62 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 63 DCA 220SSu SSJU TRAILER WIRING DIAGRAM TOWING VEHICLE SIDE TRAILER SIDE DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT WHITE SINGLE E YELLOW BROWN Ecc GREEN STOP 8 TURN LEFT LICENSE TAIL LIGHT 1 I DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT i I I 1 1 1 DOUBLE FILAMENT BULB I TO CHASSIS RIGHT GROUND TAIL LIGHT L 1 WHITE COMMON GROUND SINGLE BLACK BLUE TURN RIGHT FILAMENT 1 GREEN TAIL LICENSE BULB YELLOW STOP RED TURN LEFT LICENSE I TAIL LIGHT I I DOU
95. he engine fault must be corrected Also observe that there are no active fault codes displayed on the diagnostic panel If no fault codes are displayed place the diagnostic switch in the OFF position Figure 47 Voltmeter DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 53 DCA 220SSJ SSJU GENERATOR START UP PROCEDURE MANUAL DECREASE INCREASE Figure 48 Voltage Adjust Control Knob 14 The ammeter Figure 49 will indicate zero amps with no load applied When a load is applied the ammeter will indicate the amount of current that the load is drawing from the generator Figure 49 Ammeter No Load 15 The engine oil pressure gauge Figure 50 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure 15 approximately 35 to 65 psi 241 448 kPa When starting the generator Figure 50 Oil Pressure Gauge 16 The coolant temperature gauge Figure 51 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 180 230 F 82 110 C Green Zone Figure 51 Coolant Temperature Gauge 17 The tachometer gauge Figure 52 will indicate the speed of the engine when the generator is operating Under normal operating conditions ie this speed is approximately 1800 RPM s Figure 52 Engine Tachometer Gauge 18 Place the main and aux circuit breakers in t
96. id or correct fluid fill with dot 4 fluid Brake components loose bent or broken Replace components Locking Brakes DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 61 DCA 220SSJ SSJU MAINTENANCE TRAILER Tires Wheels Lug Nuts Suspension Tires and wheels are a very important and critical The leaf suspension springs and associated components components of the trailer When specifying or replacing the Figure 61 should be visually inspected every 6 000 miles trailer wheels it is important the wheels tires and axle are for signs of excessive wear elongation of bolt holes and properly matched loosening of fasteners Replace all damaged parts Suspension immediately Torqued suspension components CAUTION EYESIGHT HAZARD as detailed in Table 17 ALWAYS wear safety glasses when BRACKET IS WELDED TO FRAME removing or installing force fitted parts SHACKLE Failure to comply may result in serious gt pers injury HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAM BOLTS A CAUTION REPAIRING TRAILER WHEELS LEAF DO NOT attempt to repair or modify a wheel DO NOT ERONT install in inner tube to correct a leak through the rim Ifthe PANGER NUT rim is cracked the air pressure in the inner tube may cause pieces of the rim to gt AM explode break off with great force and cause serious eye or bodily injury FRONT BOLT HANGER BOLT LOCKING TIE PLATE Figure 61 Major
97. ill be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 In cases where an item is accepted for which the original purchase document can not be determined the price will be based on the list price that was effective twelve months prior to the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change Multiquip reserves the right to quote and sell direct to Government agencies and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00 surcharge will be added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip sha
98. ing Panel Figure 8 AUTO 4 MANUAL OFF RESET 9 44 LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING Figure 8 Engine Operating Panel Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position Panel Light Switch When activated will turn on control panel light Oil Pressure Gauge During normal operation this gauge be should read between 35 to 65 psi 241 448 kPa When starting the generator the oil pressure may read alittle higher but after the engine warms up the oil pressure should return to the correct pressure range Water Temperature Gauge During normal operation this gauge be should read between 180 and 230 F 82 C and 110 C Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generators control circuits and battery charging system Fuel Gauge Indicates amount of diesel fuel available Tachometer Indicates engine speed in RPM s for 60 Hz operation This meter should indicate 1800 RPM s when the rated load is applied In addition a built in hour meter will record the number of operational hours that the generator has been in use PAGE 38 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU EN
99. k while the engine DO NOT overfill tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in approved containers in well ventilated areas and away from sparks and flames Gasoline is extremely flammable and is running or hot NEVER use luel as a cleaning agent WARNING BURN HAZARDS Engine components can generate extreme heat To prevent burns DO NOT touch these areas while the engine is running or immediately after operations NEVER operate the engine with heat shields or heat guards removed A DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH PAGE 8 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU SAFETY MESSAGE ALERT SYMBOLS AX WARNING ROTATING PARTS 4 NEVER operate equipment with covers or guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury CAUTION ACCIDENTAL STARTING 2 OFF ALWAYS place the control switch in the OFF RESET position when the generator is not in use A CAUTION OVER SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings Personal injury and damage to the engine or equipment can result if operating
100. l be displayed for engines with a pre startup sequence Once the Wait to start message 1 no longer displayed the operator may start the engine Note Displays only when SAE J1939 message is supported by engine manufacturer WAIT TO START PREHEAT Once the engine has started the single engine parameter is displayed Main Menu Navigation Starting at the single or four engine parameter display touch Menu 3 4 The first seven items of the Main Menu will be displayed Touching the Arrow Buttons will scroll through the menu selection Touching the right arrow button will scroll down to reveal the last items of Main Menu screen highlighting the next item down ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES Touch the Arrows to scroll to the desired menu item or touch Menu to exit the Main menu and return to the engine parameter display 1800 RPM SNENA COOL TEMP Selecting a Language 1 Starting at the main menu display use the Arrows to scroll to the Language menu and once highlighted touch the Enter button GO TO 1 UP DISPLAY LANGUAGES STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 23 DCA 220SSu SSJU DIAGNOSTIC DISPLAY If the word MORE appears above the Arrow Buttons there are more stored fault codes that may be vie
101. les Figure 11 provided on the output terminal panel These receptacles can only be accessed when the voltage change over board is configured for three phase 240 operation 5 6369 TWIST LOCK RECEPTACLES SINGLE PHASE 240 139 VAC 50 AMP OUTPUT Figure 11 240 139V Twist Lock Auxiliary Receptacles Each auxilliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the receptacles Remember the load output current on all three receptacles is dependent on the load requirements of the Output Terminal Lugs Turn the voltage regulator control knob Figure 12 on the control panel to obtain the desired voltage Turning the knob clockwise will increase the voltage turning the knob counter clockwise will decrease the voltage DECREASE INCREASE N Figure 12 Voltage Regulator Control Knob Removing the Plastic Face Plate Hard Wire Hookup Panel The Output Terminal Lugs are protected by a plastic face plate cover Figure 13 Un screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure After the load wires have been securely attached to the terminal lugs reinstall the plastic face plate HARD WIRE HOOKUP PANEL PLASTIC TERMINAL COVER SECURING BOLTS Figure 13 Plastic Face Plate Output Terminal Lugs DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 41 DCA 220SSJ SSJU
102. ligations Your Local Dealer is MULTIQUIP
103. ll not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES No warranties express or implied are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apart from such written statement of warranty there are no warranties express implied or statutory which extend beyond the description of the products on the face hereof Effective February 22 2006 PAGE 112 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 113 OPERATION AND PARTS MANUAL HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Multiquip Corporate Office MQ Parts Department 18910 Wilmington Ave Tel 800 421 1244 800 427 1244 Fax 800 672 7877 Carson CA 90746 Fax 310 537 3927 310 537 3700
104. luence or NEVER use accessories or attachments which are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result accident due to equipment modifications Unauthorized equipment modification will void all warranties Whenever necessary replace nameplate operation and operating the DCA 220SSJ SSJU Whisperwatt AC equipment before reading this entire generator clothing shatterproof glasses steel toed boots and other feeling well due to fatigue illness taking Manufacturer does not assume responsibility for any safety decals when they become difficult read ALWAYS checkthe machine for loosened threads or bolts before starting NEVER operate the generator in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator HighTemperatures Allow the engine to cool before performing service and A maintenance functions Contact with hot components can cause serious burns ead rrr uas The engine of this generator requires an adequate free flow of cooling air NEVER operate the generator in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause serious damage to the generator or engine
105. ns to scroll through the menu until the Engine Configuration menu item has been highlighted Auxiliary Gage Fault 1 During normal operation the single or four parameter SOTO DISPLAY screen will be displayed STORED CODES SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 3 the Engine Configuration menu item has been highlighted touch the Enter Button to view the engine configuration data 2 The PVA Series of auxiliary gages can be attached to the PowerView These auxiliary gages communicate with GOTO TUP DISPLAY the Modbus master PowerView via a daisy chained RS SETUP 1 UP DISPLAY 485 port If at any time during system initialization or SELECT UNITS 7 normal operation an auxiliary gage should fail the single or four parameter screen will be replaced with the MLink Gage Fault message 4 Use the Arrow Buttons to scroll through the engine configuration data ENGINE SPEED PT 1 1800 RPM 3 acknowledge and Hide the fault and return to the single or four parameter display touch the Enter Button 1 of x ENGINE OIL PRESSURE ENGINE SPEED PT 1 1800 RPM lt q 4 The display will return to the single or four parameter screen 6 Touch the Menu Button to exit the Main menu and return to the engine parameter display DCA 220SSJ SSJU
106. nt Brake lines should be periodically checked for cracks kinks or blockage Anchor Post Springs Cylinder Backing P Plate ctuating Pin Hold Down Spring f Primary Shoe Adjuster Spring Adjuster Assembly Figure 60 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator 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 vehicle brakes As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder supplying hydraulic pressure to the trailer brakes Periodically check and test the surge actuator to make sure that it is functioning correctly Never use an undersize actuator Table 15 Hydraulic Brake Troubleshooting Symptom Possible Cause Solution Brake line broken or kinked Repair or replace Weak ae TUS Brake drums scored or grooved Machine or replace Trailer overloaded Correct weight Tires unmatched on the same axle Match tires Tire pressure correct Inflate all tires equally Brake lining glazed Reburnish or replace Brake components correct Replace and correct Brake drums out of round System lubricated Noisy Brakes Dragging Brakes Brake lining thickness incorrect or not Install new shoes and adjusted correctly linings Replace rubber parts 2 Enough brake flu
107. nt using the voltage regu lator VR control knob located on the control panel Voltage Change Over Board The voltage change over board Figure 16 is located on the control box behind the generator control panel This board has been provided for ease of voltage selection JUMPER 6 PLACES Figure 16 Voltage Change Over Board CAUTION CHANGING VOLTAGES NEVER attempt to place jumper plates on the voltage change over board while the generator is in operation There exist the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even death Table 7 Voltages Available Three Phase 220v 240 416V 440V 480V Selectable Single Phase t27v 139v 240v 254V 277V Selectable Generator Amperage Tables 8 and 9 describe the generator s current output capa bility for both 10 phase and 30 phase applications Table 8 Generator Ampere Ratings 10 W fV 240 300 150 317 125 301 PAGE 44 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU GENERATOR OUTPUTS GAUGE READING Maximum Amps Table 10 shows the maximum amps the generator can pro vide DO NOT exceed the maximum amps as listed Table 10 Generator Maximum Amps How to Read the Output Terminal Gauge The AC ammeter and AC voltmeter change over switches on the control panel DO
108. nter Button to activate the Use Defaults function USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF h A message indicating the Single Engine parameter display parameters are reset to the factory defaults will be displayed then the display will return to the Custom Setup menu Custom Setup To perform a custom setup of the 1 Up Display use the arrow buttons to scroll to and highlight Custom Setup on the display USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Touching the Enter Button will display a list of engine parameters USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Use the Arrow Buttons to scroll to and highlight a selected parameter parameter with a symbol to right of it PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE QO PAGE 30 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU DIAGNOSTIC DISPLAY 11 Touch the Enter Button to deselect the selected parameter removing it from the list of parameters being displayed on the 1 up display ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE 12 Use the Arrow Button to scroll and highlight the desired parameter that has not been selected for display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE 13 Touch the Enter Button to
109. ooa DCA220SSu 0016906020 HEX FIERO BOLD or DCA220SSJU 0601815194 TERMINAL BLOCK 1 0025304015 MACHINE SCREW uuu DCA220SSu 0027104016 MACHINE SCREW E ensi DCA220SSJU DCA220SSJU ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8 RED 4 SUNBELT GREEN 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED 9 DESERT TAN DCA220SSJ THE PART NUMBERS SHOWN ARE FOR ORANGE UNITS PLEASE ADD THE FOLLOWING LETTERS TO THE END OF THE PART NUMBER WHEN ORDERING A PAINTED PANEL OF A DIFFERENT COLOR MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 89 ur N OUTPUTTERMINAL ASSY CONT DCA220SSJ SSJU pu ss N gt E gt Lu cc lt lt lt o lt lt lt lt H lt t cc Lu a gt 9 42 9 CN c t e Lu lt 0 0601850275 0601851780 0603306775 0601808803 0601808804 C3261600704 4260600104 0222100150 0019206020 0016906020 0601812598 0601812565 0601812538 0025304015 0027104016 0207004000 4236400204 0019206015 0016906016 4236100303 0010112045 0041212000 0805009804 M9310200004 0030012000 0605011505 00253
110. r Cleaner with Dust Indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator Service Daily If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists Fuel Addition Add diesel fuel the grade may vary according to season and locations Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally inspect the fuel tank for water contamination and drain the contents if required During cold weather the more empty volume inside the tank the easier it is for water to condense This can be reduced by keeping the tank full with diesel fuel DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 57 DCA 220SSJ SSJU MAINTENANCE ENGINE Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system according to the following procedure See the
111. r from the voltage regulator 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 rectified and are the excitation current for the exciter section When a heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of B to C This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands of the required load Engine The DCA 220SSJ SSJU is powered by a 6 cylinder water cooled direct injection turbocharged John Deere 6068HF485 Turbo Diesel Engine This engine is designed to meet every performance requirement for the generator Reference Table 1 for engine specifications In keeping with MQ Power s policy of constantly improving its products the specifications quoted herein are subject to change without prior notice Electric Governor System The electric governor system controls the RPMs of the en gine
112. r the HIGH COOLANT TEMPERATURE engine has been started OVERCRANK OVERSPEED ENGINE RUNNING 5 Place the Diagnostic ON OFF switch in the ON position Verify that an Active Fault Code message is being displayed Diagnostic Display Panel The fault code message will continued to be displayed until the fault has been corrected Figure 43 shown below is a typical example of an active fault code message Low Figure 45 Engine Running LED ON Radiator Coolant DIAGNOSTIC 11 Observe that the Warning and Emergency Stop lamps on the Engine Operating Panel are OFF 12 The generator s frequency meter Figure 46 should be displaying the 60 cycle output frequency in HERTZ Figure 43 Active Fault Code Message 6 In a situation where several engine problems occur simultaneously the word MORE appears above the Figure 46 Frequency Meter Hz arrow buttons indicating that there are more fault codes that need to be viewed Use the arrow buttons to scroll 13 The generator s AC voltmeter Figure 47 will display the to the next active fault code generator s output in VOLTS If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 48 to increase or decrease the desired voltage If desired the type of fault code cause of error and the countermeasures of the error can be referenced in a separate engine operator s manual 7 Before the engine can be started t
113. rating the machine has e Turn power off before sufficiently cooled 54515555 servicing P N M9510100004 P N M9520100503 e WARNING ___ ELECTRIC SHOCK HAZARD e Do not touch internal wiring or connections while this machine is operating e Turn power off before servicing CAUTION This machine stops and starts Automatically and without notice P N B15200010 M92010000 P N B15200010 P N M9520100004 Figure 3 Generator Decals Cont inued DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 15 DCA 220SSJ SSJU INSTALLATION Z GROUND ROD FOR EARTH GROUND GROUND LUG ENA CONNECT TO BUILDING GROUND GROUND CABLE x 8 MINIMUM 2508 Figure 4 Typical Generator Grounding Application PAGE 16 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU INSTALLATION Outdoor Installation Install the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration
114. rator Control 37 Engine Operating Panel 30 39 Output Terminal Panel Familiarization 40 42 p u uuu 43 Generator Outputs 44 Calle FACING uuu uuu 45 Output Terminal Panel Connections 46 47 wi m 48 51 Generator Start up Procedure Manual 52 54 Generator Start up Procedure Auto Mode 55 Generator Shut Down Procedure 56 Maintenance Engine 57 58 Maintenance Jacket Water Heater Battery Charger 59 Maintenance Trailer 60 63 Traiter Diagram t shee uuu u uuu uu 64 Generator Wiring Diagram 65 u u u uu u u uuu uu uuu 66 Generator Troubleshooting 67 Engine Controller Troubleshooting 68 Explanation of Code in Remarks Column 70 Suggested Spare 71 COMPONENT DRAWINGS Generator 5 72 75 Control Panel Assembly 76 77 Control Box
115. rovide complete instructions for the safe and efficient operation of the MQ Power Model DCA 220SSJ SSJU Whisperwatt Generator Before using this generator ensure that the operatin individual has read and understands all instructions in this manual SAFETY MESSAGE ALERT SYMBOLS The three 3 Safety Messages shown below will inform you about potential hazards that could injure you or others The Safety Messages specifically address the level of exposure to the operator and are preceded by one of three words DANGER WARNING or CAUTION You WILL be KILLED or 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 HAZARD SYMBOLS Potential hazards associated with the operation of this equipment will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols WARNING LETHAL EXHAUST GASES Gasoline engine exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause DEATH if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air WARNING EXPLOSIVE FUEL its vapors can cause an explosion if ignited DO NOT start the engine near spilled fuel or combustible fluids DO NOT fill the fuel tan
116. s extremely dangerous ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required Backfeed to a utility system can cause electrocution and or property damage DO NOT connect to any building s electrical system except through an approved device or after building main switch is opened ALWAYS have a licensed electrician perform the installation WET HANDS 6 RL CORD POWER ON DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 11 DCA 220SSJ SSJU RULES FOR SAFE OPERATION Maintenance Safety he electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers OFF before performing maintenance on the generator NEVER lubricate components or attempt service on a running machine ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator ALWAYS allow the machine a proper amount of time to cool before servicing Keep the machinery in proper running condition Fix damage to the machine immediately and always replace broken parts ALWAYS service air cleaner frequently to prevent engine malfunction WARNING BURN HAZARDS To prevent burns
117. select the highlighted parameter for inclusion in the Single Engine Parameter Display ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMPERATURE 3 14 Continue to scroll and select additional parameters for the custom 1 up Display Touch the Menu Button at any time to return to the Custom Setup menu 15 Automatic Scan Selecting the scan function will cause the 1 Up Display to scroll through the selected set of parameters one at a time Use the Arrow Buttons to scroll to the Automatic Scan function 16 Touching the Enter Button toggles the Automatic Scan function on 17 Touchingthe Enter Button again toggles the Automatic Scan function off 18 Oncethe Use Defaults Custom Setup and Automatic Scan functions have been set touch the Menu Button to return to the main menu USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON 19 Touch the Menu Button to exit the Main menu and return to the engine parameter display STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT DCA 220SSJU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 31 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Setup 4 Up Display 5 The Use Defaults screen will be displayed during the 1 From the single or four engine parameter display touch resetting period then will automatically return to the t
118. splay touch the Menu Button BATT Vi The main menu will pop up on the display Use the Arrow Buttons to scroll through the menu until the Setup 1 up Display is highlighted SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 29 DCA 220SSu SSJU DIAGNOSTIC DISPLAY 3 Once the Setup 1 up Display menu icon has been highlighted touch the Enter Button to access the Setup 1 up display function GO TO 1 UP DISPLAY STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNI TS ADJUST BACKLIGHT Three options are available for modification of the 1 Up display a Use defaults This option contains a set of engine parameters Engine Hours Engine RPM System Voltage Battery Voltage Engine Load at Current RPM Coolant Temperature Oil Pressure Custom Setup This option allows for the modification of what parameter the number of parameters and the order in which the parameters are being displayed c Automatic scan Selecting the scan function will cause the 1 Up Display to scroll through the selected set of parameters one at a time momentarily pausing at each Use Defaults To select Use Defaults use the arrow buttons to scroll to and highlight Use Defaults in the menu display USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF Touch the E
119. splayed message is not supported DATA ERROR Diagnostic Display has received an error message from the ECU for the displayed message EMPTY No parameter selected for this 4 UP quadrant WAIT TO START PREHEATING This is a message from the engine indicating it is in a preheating cycle Wait until this message clears before starting the engine TIMEOUT ECU NOT RESPONDING The ECU did not respond to the PowerView request NO GAGE DATA The Diagnostic Display has no record of connected gages to the RS485 bus DISPLAY NOT VISIBLE Press and hold the Menu button for approximately 3 seconds PAGE 36 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSJ SSJU GENERATOR CONTROL PANEL Figure 7 Generator Control Panel The definitions below describe the controls and functions of the DCA 220SSJ SSJU Generator Control Panel Figure 7 1 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 2 ACAmmeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 3 Ammeter Change Over Switch This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals or to be switched off This switch does not effect the generator output in any fashion it is for current reading only 4 Voltage Regulator Control Allows 15 manual adjustment of th
120. tarting allow the engine to runfor 1 or 2 minutes to Stopping Place the Generator Circuit Breakers in the OFF position Set the Engine speed switch to the LOW position and allow the unit to cool for few minutes 3 Turn the Auto OfffReset Manual switch to the OfffReset position Gne Starting Stopping With the Auto Manual switch in the Auto position the Auto Starting Stepping controller monitors remote start contacts Closure of the remote start contacts will begin engine cranking When the contacts are opened cranking will stop or if running the engine will stop All funcitons fo the Automatic shutdown System work as in Manual Starting stopping For cold weather conditions utilize the water heater until water is warm If the engine still does not start please operate as in Manual Starting Emergency Stopping 1 Place the Generator Circuit Breakers in the OFF position 2 Turn the Auto OfffReset Manual switch to the OffiReset position SAFETY INSTRUCTIONS Improper operation of this machine can cause Severe injury or death Read the instruction manual carefully before operating or servicing This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation High voltage circuits are located inside the warm up At temperatures below freezing this time period must be extended to 2 to 4 minutes 8 When the engine st
121. ter Heater and Internal Battery Charger 120 Input Receptacles OPTIONAL This generator can be optionally equipped with two 120 VAC 20 amp input receptacles located on the output terminal panel The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 59 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 When using the generator in hot climates there 15 no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size If the generator will be used daily the battery should normally not require charging If the generator will be idle not used for long periods of time apply power to the battery charger receptacle via commercial power using an power cord of adequate size NOTICE To ensure adequate starting capability always have power applied to the generators internal battery charger OUTPUT TERMINAL BATTERY CHARGER 120 VAC INPUT RECEPTACLE CONNECT TO EXTERNAL 120 VAC POWER SOURCE PANEL JACKET W
122. tion a list must be provided to Multiquip Parts Sales that defines item numbers quantities and descriptions of the items to be returned The parts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated The list must state the reason s for the return d The list must reference the sales order s or invoice s under which the items were originally purchased e The list must include the name and phone number of the person requesting the RMA 3 Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 The following items are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior to the return date c Any line item with an extended dealer net price of less than 5 00 d Special order items e Electrical components f Paint chemicals and lubricants g Decals and paper products h ltems purchased in kits 7 The sender w
123. touch Select An asterisk denotes which version is currently selected NOTE There are four 4 different methods for converting fault codes The diagnostic display always looks for J1939 Version 4 and can be set to read the code as one of three 3 other J1939 versions if Version 4 is not being used Most engine ECU s use Version 4 therefore in most cases adjustment of this menu option will not be required Upon receiving an unrecognizable fault change to a different J1939 Version If the fault SPN does not change when the version is changed the ECU generating the fault is using Fault Conversion method 4 If the SPN number does not change but is still unrecognizable try changing to another J1939 Version not yet used and continue to check the SPN number 41939 VERSION 1 41939 VERSION 2 41939 VERSION 3 PAGE 34 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 11 DCA 220SSu SSJU DIAGNOSTIC DISPLAY Touch the Menu button to return to Utilities menu Touch the Menu button again to return to the Main menu STORED CODES ENGINE CONFG SETUP 1 UP DISPLAY SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES MODBUS SETUP 1 Starting at the single or four engine parameter display touch the Menu Button The main menu will be displayed Use the Arrow Buttons to scroll through the menu until the Utilities is highlighted then touch Enter
124. trical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground a Copper 8 AWG 5 3 mm b Aluminum 6 AWG 8 4 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 the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies that the earth ground rod should be buried a minimum of 8 ft into the ground NOTICE When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician DCA 220SSU SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 PAGE 17 DCA 220SSu SSJU GENERAL INFORMATION DCA 220SSu SSJU Whisperwatt Series Familiarization Generator The MQ Power Model DCA 220SSU SSJU is 176 kW generator Figure 5 that is designed as a high quality portable requires a trailer for transport power source for telecom sites lighting facilities power tools submersible pumps and other industrial and construction machinery Engine Operating Panel The Engine Operating Panel is provided with the following Tachometer Water T
125. wed Use the Arrow Buttons to scroll to the next Stored Diagnostic Code 2 3 The language choices will be displayed Use the Arrow 4 buttons to scroll through the selections and touch Enter to make a selection ESPANOL FRANCAIS DEUTSCH Now that you have selected the language touch the Menu button to return to the main menu display Stored Fault Codes 1 Starting at the single or the four engine parameter display touch the Menu button The main menu will pop up on the display Use the Arrow Buttons to scroll through the menu until the Stored Fault Codes is highlighted Once the Stored Fault Codes menu item has been highlighted touch the Enter Button to view the Stored Fault Codes when applicable consult engine or transmission manufacturer for SAE J1939 supported parameters PAGE 24 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 B SPN110 FMI10 HIGH COOLANT TEMP Touch the Menu Button to exit the Main menu and return to the engine parameter display SETUP 4 UP DISPLAY SELECT UNITS ADJUST BACKLIGHT Engine Configuration Data 1 Starting at the single or four engine parameter display touch the Menu Button 1800 RPM easi COOL TEMP DCA 220SSu SSJU DIAGNOSTIC DISPLAY 2 The main menu will pop up on the display Use the Arrow FAULTS AND WARNINGS Butto
126. wn the generator 6 Warning LED When lit AMBER indicates a engine parameter has exceeded its limits minor fault The generator will still run in this condition 7 Display Screen Graphical backlight LCD screen Back lighting is controlled via menu or external dimmer potentiometer The display can show either a single parameter or a quadrant display showing four parameters simultaneously 8 Diagnostic Switch When placed in the ON position will activate the diagnostic display panel 9 CAN Diagnostic Connector Controller Area Network connector This connector outputs diagnostic error codes Connect a scanner or similar device into this connector to read error codes Display Parameters The following are some of the engine and transmission parameters displayed on the diagnostic disply panel Engine RPM s Engine Hours System Voltage e Engine Load at current RPM Coolant Temperature Oil Pressure Fuel Economy Current Fuel Consumption Throttle Position Engine Manifold Air Temperature Active Service Codes Set Units for Display English or Metric English Configuration Parameters PAGE 20 DCA 220SSJ SSJU OPERATION AND PARTS MANUAL REV 1 02 28 14 DCA 220SSu SSJU DIAGNOSTIC DISPLAY First Time Start Up 1 When power is first applied to the diagnostic display the Logo is displayed The Wait to Start message will be displayed for engines with a pre startup sequence
127. y for a 5 Discount Parts rts log in and save on Standard orders for all orders which include IS i complete part numbers d a p Order Fax Dealers Only Fax your order in and qualify for a 2 Discount All customers are welcome to order parts via Fax on Standard orders for all orders which include Domestic US Customers dial part numbers 1 800 6 PARTS 7 800 672 7877 ai ee Note Discounts Are Subject To Change Order via Phone 1 800 427 1244 Uug ZW Domestic US Dealers Call ee lt lt lt 7 Non Dealer Customers iba Multiquip Dealer for International Customers should contact parts or call 800 427 1244 for help in their local Multiquip Representatives for locating a dealer near you Parts Ordering information U 4 ___________________ __ _ _ When ordering parts please supply Dealer Account Number C Specify Preferred Method of Shipment Dealer Name and Address UPS Fed Ex DHL Shipping Address if different than billing address Priority One v Truck Return Fax Number Ground Next Applicable Model Number WI Second Third Day Quantity Part Number and Description of Each Part NOTICE All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST

Multiquip C1870300404 Portable Generator User Manual

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