Multiquip DCA-220SSJ User Manual 2

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-220SSJ

60 Hz GENERATOR

PARTS LIST NO. C1870300404

Revision #1 (03/22/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

NOTE PAGE

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 3

MQ POWER DCA-220SSJMQ POWER DCA-220SSJ

MQ POWER DCA-220SSJ

MQ POWER DCA-220SSJMQ POWER DCA-220SSJ

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

California Proposition 65 Warning ..................................... 2

Table Of Contents ............................................................. 4

Parts Ordering Procedures ............................................... 5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Diagnostic Display ..................................................... 20-36

Generator Control Panel ................................................. 37

Engine Operating Panel ............................................. 38-39

Output Terminal Panel Familiarization ........................ 40-42

Load Application ............................................................. 43

Generator Outputs .......................................................... 44

Gauge Reading ............................................................... 45

Output Terminal Panel Connections ................................ 46

Setup .............................................................................. 47

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

Trailer Wiring Diagram .....................................................64

Generator Wiring Diagram ............................................... 65

Engine Wiring Diagram ................................................... 66

Generator Troubleshooting .............................................. 67

Engine Controller Troubleshooting ................................... 68

Explanation of Code in Remarks Column ....................... 70

Suggested Spare Parts .................................................. 71

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 72-74

Control Panel Assembly ............................................ 76-77

Control Box Assembly ............................................... 78-81

Engine and Radiator Assembly ................................. 82-87

Output Terminal Assembly ......................................... 88-89

Battery Assembly ...................................................... 90-91

Muffler Assembly ...................................................... 92-93

Fuel Tank Assembly .................................................. 94-95

Enclosure Assembly ...............................................

Rubber Seals Assembly ........................................ 102-103

Nameplate and Decals .......................................... 104-105

Terms and Condition of Sale — Parts .......................... 106

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

96-101

PAGE 4 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00

list price) do not count towards the 10+ line items.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-220SSJ — SPECIFICATIONS

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)WK491(AVK242

)WK671(AVK022

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8.0

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)2XWK4.2(WK8.4

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).gk03

).gk025,3(.sbl357,7

snoitacificepSenignE.2elbaT

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)mm721xmm601(.ni00.5x.ni71.4

MPR0081/.P.H682

)sretil8.6(.ni.uc

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)sretil42(.lag4.6

)sretil13(.lag91.8

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)sretil083(.lag001

tarh/)L6.15(.lag36.31 daollluf

1xhA821

PAGE 6 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIMENSIONS (TOP, SIDE AND FRONT)

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm049(.ni00.73F ).mm005,3(.ni08.731

B).mm0

C).mm050,1(.ni33.14H ).mm042,1(.ni18.84

D).mm050,1(.ni33.14

E).mm050,1(.ni33.14

49(.ni00.73G ).mm007,1(.ni29.66

Figure 1. Dimensions

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 7

).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

DCA-220SSJ — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE 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

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-220SSJ

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating 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.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

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.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

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.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-220SSJ — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the MPEC control switch

in the OFF/RESET position when the generator is not in use.

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 in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

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.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 9

DCA-220SSJ — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the

General Safety:

■

DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

or even

DEATH

! This equipment is to be

DCA-220SSJ Whisperwatt™ AC Generator.

ALWAYS check the 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

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. 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 and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

bodily harm or even death.

NEVER

operate the generator in any

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

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.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

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 unattended.

Refer to the 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.

John Deere Engine Owner's Manual

manual mode

for

PAGE 10 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(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:

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

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution 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.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

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

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

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

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 11

DCA-220SSJ — RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the 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, 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 drain 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.

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, 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

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the 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.

In case the battery liquid (dilute sulfuric acid) comes in contact with immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

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.

PAGE 12 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — RULES FOR SAFE OPERATION

■

Towing & 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 state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed 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 a trailer with defective hitches, couplings, chains etc.

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

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 while parked.

■

Use the trailer’s 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 prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

Check the tire air pressure on both towing vehicle and trailer. 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:

z z

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

DCA-220SSJ — GENERATOR DECALS

The DCA-220SSJ generator is equipped with a number of safety decals (Figures 2 & 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.

Figure 2. Generator Decals

PAGE 14 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 15

DCA-220SSJ — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — 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 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.

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

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.

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 - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

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 aminimum of 8 ft. into the ground.

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.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 17

DCA-220SSJ — GENERAL INFORMATION

DCA-220SSJ Whisperwatt™ Series Familiarization

Open Delta Excitation System

The DCA-220SSJ generator is equipped with the state of

Generator

The MQ Power Model DCA-220SSJ is a 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 Temperature 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

■■

the art " 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 power 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

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 (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

excitation does not have a " according the demands of the required load.

Engine

The DCA-220SSJ is powered by a 6 cylinder, water cooled, direct injection, turbocharged

Diesel Engine

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 engine. 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.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

John Deere 6068HF485 Turbo

. This engine is designed to meet every

PAGE 18 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — MAJOR COMPONENTS

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.ONMETINOITPIRCSED

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2ylbmessAselcatpeceRtuptuO

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4ylbmessArelffuM

5ylbmessAknaTleuF

6ylbmessAenignE

7ylbmessAyrettaB

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Figure 5. Major Components

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 19

DCA-220SSJ — DIAGNOSTIC DISPLAY

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 shudown 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.

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 keypad (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 Operator’s 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).

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

■■

■

% 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.

■■

1. Menu Button – Press this button to enter or exit menu screens.

2. Left Arrow Button– Press this button to scroll through the screen either moving the parameter selection toward the left or upward.

PAGE 20 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

First Time Start Up

1. When power is first applied to the diagnostic display, the “Logo” is displayed.

2. The “Wait to Start” message will be displayed for engines with a pre-startup sequence. Once the “Wait to Start” message is 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

2. The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll through the menu selection.

GO TO 1-UP DISPLAY

LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

3. 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

3. Once the engine has started the single engine parameter is displayed.

1500

3000

1800 RPM

TEMP

ENG RPM

COOL

Main Menu Navigation

1. Starting at the single or four engine parameter display, touch “Menu”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

4. 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.

1000 RPM

3000

1500

98%

LOAD RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

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 CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 21

DCA-220SSJ — DIAGNOSTIC DISPLAY

2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection.

4. 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.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

3. Now that you have selected the language, touch the “Menu” button to return to the main menu display.

5. Touch the “Menu Button to return to the main menu.

Stored Fault Codes

1. Starting at the single or the four engine parameter display touch the “Menu button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

2. 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.

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

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).

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

Engine Configuration Data

1. Starting at the single or four engine parameter display touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

PAGE 22 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

First Time Start Up

1. When power is first applied to the diagnostic display, the “Logo” is displayed.

WAIT TO

START

PREHEAT

2. The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll through the menu selection.

GO TO 1-UP DISPLAY

LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

3. 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

3. Once the engine has started the single engine parameter is displayed.

1500

3000

1800 RPM

TEMP

ENG RPM

COOL

Main Menu Navigation

1. Starting at the single or four engine parameter display, touch “Menu”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

4. 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.

1000 RPM

3000

1500

98%

LOAD RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

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 CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 23

DCA-220SSJ — DIAGNOSTIC DISPLAY

2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection.

4. 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.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

3. Now that you have selected the language, touch the “Menu” button to return to the main menu display.

5. Touch the “Menu Button to return to the main menu.

Stored Fault Codes

1. Starting at the single or the four engine parameter display touch the “Menu button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

2. 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.

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

Engine Configuration Data

1. Starting at the single or four engine parameter display touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

PAGE 24 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

2. The main menu will pop up on the display. Use the “Arrow

FAULTS AND WARNINGS

Buttons” 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

GO TO 1-UP DISPLAY STORED CODES

ENGINE CONFG

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

screen will be displayed.

1800 RPM

ENG RPM

3. Once 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

GO TO 1-UP DISPLAY STORED CODES

ENGINE CONFG

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

the Modbus master PowerView via a daisy-chained RS485 port. If at any time during system initialization or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the “MLink Gage Fault” message.

1500

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

4. Use the “Arrow Buttons” to scroll through the engine configuration data.

ENGINE SPEED PT 1

1800 RPM

3. To acknowledge and “Hide” the fault and return to the single or four parameter display, touch the “Enter Button”.

5. Touch the “Menu Button” to return to the main menu.

ENGINE SPEED PT 1

1800 RPM

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.

1800 RPM

ENG RPM

1500

COOL

1ofx

ENGINE OIL PRESSURE

GAGE NOT RESPONDING

1ofx

ENGINE OIL PRESSURE GAGE NOT RESPONDING

3000

TEMP!

HIDE

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 25

DCA-220SSJ — DIAGNOSTIC DISPLAY

Indicates Auxiliary Gage Fault

Indicates Fault Warning

Indicates Derate or Shutdown Condition Fault

4. To acknowledge and “Hide” the fault and return to the single or four parameter display touch the “Enter Button”.

5. 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 GAGE NOT RESPONDING

HIDE

5. 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.

Active Fault Codes

1. During normal operation the single or four parameter

1800 RPM

ENG RPM

screen will be displayed.

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

6. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

1500

COOL

3000

TEMP!

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

LOAD RPM

BATTVOLT

98%

14.2

1000 RPM

ENG RPM

57 PSI

OIL PRES

2. 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.

1ofx

WARNING

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

7. 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.

3. 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”.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1ofx

WARNING

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

PAGE 26 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

Shut Down Codes

1. During normal operation the single or four parameter screen will be displayed.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

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.

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

5. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

6. 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.

1800 RPM

ENG RPM

1500

COOL

3000

TEMP!

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

3. To 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

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

touch the “Menu Button”.

ENG RPM

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 menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until the “Adjust Backlight” is highlighted.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP!

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

1500

1800 RPM

COOL

3000

TEMP

GO TO 1-UP DISPLAY STORED CODES

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

GENGINE CONF

1000 RPM

ENG RPM

57 PSI

OIL PRES

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 27

DCA-220SSJ — DIAGNOSTIC DISPLAY

3. Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Backlight” function.

GO TO 1-UP DISPLAY STORED CODES

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

ADJUST BACKLIGHT

GENGINE CONF

4. Use the “Arrow Buttons” to select the desired backlight intensity.

Contrast Adjustment

1. Starting at the single or four engine parameter display, touch the “Menu Button”.

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until “Adjust Contrast” is highlighted.

ADJUST BACKLIGHT

5. Touch the “Menu Button” to return to the main menu.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

3. Once the “Adjust Contrast” menu item has been

ADJUST BACKLIGHT

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

4. Use the “Arrow Buttons” to select the desired contrast

5. Touching the “Menu Button” will take you back through

highlighted touch the “Enter Button” to activate the “Adjust Contrast” function.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

ADJUST CONTRAST

intensity.

ADJUST CONTRAST

the menus.

PAGE 28 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

Select Units

5. Touch the “Enter Button” to select the highlighted units.

1. Starting at the single or four engine parameter display touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

ENG RPM

57 PSI

OIL PRES

1000 RPM

6. Touch the “Menu Button” to return to the “Main Menu”.

2. The main 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 CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY

SELECT UNITS

ADJUST BACKLIGHT

7. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES

3. Once the “Select Units” menu item has been highlighted touch the “Enter Button” to access the “Select Units” function.

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

ENGLISH

METRIC KPA METRIC BAR

ENGLISH

METRIC KPA METRIC BAR

1000 RPM

98%

LOAD RPM

14.2

BATTVOLT

ENG RPM

57 PSI

OIL PRES

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY

SELECT UNITS

ADJUST BACKLIGHT

Setup 1- Up Display

1. Starting at the single engine parameter display, touch the “Menu Button”.

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, “C.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

1800 RPM

ENG RPM

2. 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.

1500

COOL

3000

TEMP

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF

SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 29

DCA-220SSJ — 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.

7. 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.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF

SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

4. Three options are available for modification of the 1-Up display.

8. Custom Setup- To perform a custom setup of the 1-Up Display, use the arrow buttons to scroll to and highlight

a). Use defaults- This option contains a set of engine

“Custom Setup” on the display.

parameters: Engine Hours, Engine RPM. System Voltage, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, Oil Pressure.

b). 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.

RESTORED TO

DEFAULTS

USE DEFAULTS

CUSTOM SETUP

AUTOMATIC SCAN OFF

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.

5. 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

6. Touch the “Enter Button” to activate the “Use Defaults” function.

USE DEFAULTS

CUSTOM SETUP AUTOMATIC SCAN OFF

9. Touching the “Enter Button” will display a list of engine parameters.

USE DEFAULTS

CUSTOM SETUP

AUTOMATIC SCAN OFF

10. Use the “Arrow Buttons” to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).

ENGINE SPEED

PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE

3 2

This number indicates the order of display for the parameters and that the parameter is selected for display.

PAGE 30 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

11. Touch the “Enter Button” to deselect the selected parameter removing it from the list of parameters being

16. Touching the “Enter Button” toggles the “Automatic Scan” function on.

displayed on the 1-up display.

ENGINE SPEED

PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE

3 2

17. Touching the “Enter Button” again toggles the “Automatic

12. Use the “Arrow Button” to scroll and highlight the desired

Scan” function off.

parameter that has not been selected for display.

ENGINE SPEED PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

2 1

Note that the numbers now indicate the new order of display for the parameters.

18. Once the “Use Defaults”, “Custom Setup” and “Automatic

13. Touch the “Enter Button” to select the highlighted parameter for inclusion in the Single Engine Parameter

Scan” functions have been set touch the “Menu Button” to return to the main menu.

Display.

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN ON

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN OFF

ENGINE SPEED PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

2 1

19. Touch the “Menu Button” to exit the Main menu and

14. Continue to scroll and select additional parameters for

return to the engine parameter display. 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

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

parameters one at a time. Use the “Arrow Buttons” to scroll to the “Automatic Scan” function.

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN OFF

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN ON

1800 RPM

ENG RPM

1500

COOL

3000

TEMP

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 31

DCA-220SSJ — DIAGNOSTIC DISPLAY

Setup 4-Up Display

1. From the single or four engine parameter display touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

5. The “Use Defaults” screen will be displayed during the resetting period then will automatically return to the “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 4Up Display” is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG 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 highlighted touch the “Enter Button” to activate the

the parameter value in the quadrant you wish to place a new parameter.

“Setup 4- Up Display” menu.

RESTORED TO

DEFAULTS

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

USE DEFAULTS

CUSTOM SETUP

8. Touch the “Enter Button” and a list of parameters will appear.

125°F

COOL TEMP

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

PAGE 32 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

9. 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 ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

The number to the right

of the parameter indicates the quadrant in which it

is displayed. 1= Upper Left Quadrant

2 = Lower Left Quadrant 3 = Upper Right Quadrant 4 = Lower Right Quadrant

15. Touch the “Menu Button” to exit the Main menu and

return to the engine parameter display.

10. Touch the “Enter Button” to change the selected parameter in the quadrant to the new parameter.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

1 2

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY

SELECT UNITS ADJUST BACKLIGHT

Utilities

1. Starting at the single or four engine parameter display,

11. Use the “Menu Button” to return to the “4-Up Custom

touch the “Menu Button”.

Setup” screen.

125°F

COOL TEMP

OIL TEMP

143°F

1000 RPM

ENG RPM

57 PSI

OIL PRES

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

(information and troubleshooting)

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location

1800 RPM

ENG RPM

2. The main menu will be displayed. Use the “Arrow Buttons”

12. The parameter in the selected quadrant has changed to the parameter selected in the previous screen.

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

to scroll through the menu until the “Utilities” is highlighted.

3. Once the “Utilities” menu item has been highlighted, touch the “Enter Button” to activate the “Utilities” functions.

13. Repeat the parameter selection process until all spaces are filled.

1500

COOL

3000

TEMP

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 33

DCA-220SSJ — DIAGNOSTIC DISPLAY

4. 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,

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.

half duplex.

GAGE DATA

REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULTCONVERSION ADJUST BACKLIGHT DEMO MODE ON

9. Touch “Menu” to return to “Utilities”. Highlight Fault

5. Use the “Arrow Buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu.

1ofx

ENGINE OIL PRESSURE

ADDRESS:20 SOFTWARE REVISION #: ERRORS: NONE

Conversion” using the “Arrows”. Touch “Select” to enter the Fault conversion menu.

SOFTWARE

VERSION

MURPHY: X.XX

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION

FAULT CONVERSION

6. Touch “Menu Button” to return to the “Utilities” menu.

1ofx

ENGINE OIL PRESSURE

ADDRESS:20 SOFTWARE REVISION #: ERRORS: NONE

7. 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

10. Use the “Arrows” to scroll to and highlight the desired version then 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.

J1939 VERSION 1

J1939 VERSION 2 J1939 VERSION 3

PAGE 34 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — DIAGNOSTIC DISPLAY

11. Touch the “Menu” button to return to “Utilities” menu. Touch the “Menu button again to return to the “Main” menu.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

4. 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.

MODBUS SETUP

1. Starting at the single or four engine parameter display, touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it, then touch “Enter”.

1800 RPM

14.2

ENG RPM

COOL

TEMP

BATTVOLT

2. The main menu will be displayed. Use the “Arrow Buttons” to scroll through the menu until the “Utilities”

57 PSI

OIL PRES

6. Use the “Arrow” button to scroll to each selection to configure the MODBUS values for your application.

is highlighted, then touch “Enter”.

USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESSSETUP

MASTER ACTIVE

USE FACTORY DEFAULT

SERIAL PORT SETUP

SOFTWARE VERSION SLAVE ADDRESSSETUP MASTER ACTIVE

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu until the “Modbus Setup” menu is

7. When finished, touch “Menu” to return to the previous screen.

highlighted, then touch “Enter”.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION

MODBUS SETUP

FAULTCONVERSION

BAUD RATE

PARITY

DATABITS STOP BITS

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 35

DCA-220SSJ — 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 displayed 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— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR CONTROL PANEL

Figure 7. Generator Control Panel

The definitions below describe the controls and functions of the DCA-220SSJ

Generator Control Panel

(Figure 7).

1. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz.

2. AC Ammeter – 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

Located behind the generator control panel is the

Control Box

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

■■

generator output in any fashion, it is for current reading only.

4. Voltage Regulator Control – Allows ±15% manual

NOTE

adjustment of the generator’s output voltage.

5. AC Voltmeter – Indicates the output voltage present at the

U,V, and W Output Terminal Lugs

In the event of a short circuit or over current condition, it will

6. Voltmeter Change-Over Switch – This switch allows

automatically trip the 600 amp main breaker.

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

7. Main Circuit Breaker – This three-pole, 600A main breaker is provided to protect the the

Terminal Lugs

from overload.

U,V, and W Output

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 37

DCA-220SSJ — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-220SSJ

Engine Operating Panel

(Figure 8).

Figure 8. Engine Operating Panel

1. 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.

2. Panel Light Switch – When activated will turn on control panel light.

3. 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 a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

PAGE 38 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

4. Water Temperature Gauge – During normal operation

5. Charging Ammeter Gauge – Indicates the current

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

this gauge be should read between 180° and 230°F. (82° C and 110° C

being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

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.

DCA-220SSJ — ENGINE OPERATING PANEL

8. Engine Speed Switch – This switch controls the speed

of the engine (low/high).

9. Pre-Heat Lamp – When lit, indicates engine is in the pre-heating mode (for starting during cold weather operating conditiions). When lamp goes off engine is ready for starting.

10. Warning Lamp – This lamp will illuminate when a critical engine fault has occured.

11. Emergency Stop Lamp – This lamp will illuminate when the emergency stop button has been pressed or a critical engine fault has occured.

12. Emergency Stop Button – In the event of an emergency, press this button to shutdown the generator.

13. 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.

14. 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 controller will evaluate the fault and all major faults will shutdown the generator. During

cycle

, The MPEC will attempt to crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s

Crank Protection

(RPM's) that is not safe, the controller will shutdown the engine by initializing the

mode. If the engine engages at a speed

cranking

Over Speed Protection

mode.

Over

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.

B. 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

C. High Coolant Temperature – 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

D. 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 fault.

fault.

major

fault.

major

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

F. Engine Running – Indicates that engine is running at

a safe operating speed.

major

fault.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 39

DCA-220SSJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 9) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

lugs.

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

Two (2) 100V GFCI receptacles @ 20 amp

■

■■

Two (2) GFCI Circuit Breakers @ 20 amps

■

■■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■

■■

NOTE

Terminal legs “O” and “Ground” are considered

bonded grounds

” (Figure 8) is provided with the

Figure 9. Output Terminal Panel

PAGE 40 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

100 VAC GFCI 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 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 being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 10) in

Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

plate cover (Figure 13). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

voltage regulator control knob

increase

decrease

Figure 12. Voltage Regulator Control Knob

the voltage, turning the knob counter-

the voltage.

are protected by a plastic face

(Figure 12) on the

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 10. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240/139V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 11) provided on the output terminal panel.These receptacles can when the voltage change-over board is configured for

phase 240 operation.

only

be accessed

three-

Figure 13. Plastic Face Plate (Output Terminal Lugs)

Figure 11. 240/139V Twist-Lock

Auxiliary Receptacles

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 41

DCA-220SSJ — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

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 switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convienience receptacles (Figure 14).

main

circuit breaker is provided. Make sure to

Ouput

Over Current Relay

over current relay

An 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 rent relay must be pressed. The over current relay is located in the control box.

(Figure 15) is connected to the main

reset button

Figure 15. Over Current Relay

on the over cur-

Figure 14. Connecting Loads

PAGE 42 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

, 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 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

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the appliance or tool and overheat the cable. See Table 6.

■■

■

When connecting a resistance load such as an

■■

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.

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

Motors and motor-driven equipment draw much greater current for starting than during operation.

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DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 43

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

DCA-220SSJ — GENERATOR OUTPUTS

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Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the

voltage change-over board

(Figure 15).

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the

lator

(VR)

control knob

located on the control panel.

voltage regu-

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.

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Figure 16. Voltage Change-Over Board

CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the

change-over board

There exist the possibility of

while the generator is in operation.

electrocution, electrical

voltage

shock or burn, which can cause severe bodily harm or even death

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PAGE 44 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR OUTPUTS/ GAUGE READING

Maximum Amps

Table 10 shows the vide. DO NOT exceed the maximum amps as listed.

maximum

ledoMJSS022ACD

amps the generator can pro-

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Figure 17. AC Voltmeter

Change-Over Switch

spma925

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How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO 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 3Ø, 240V operation place the

Over Switch

(Figure 17) to the W-U position and the

Ammeter Change-Over Switch

AC Voltmeter Change-

(Figure 19) to the U or W

Figure 19. AC Ammeter

Change-Over Switch

position. Use the AC voltmeter or AC ammeter (Figures 18 and 20) to read the output on the selected leg of the UVWO terminals.

Figure 18. AC Voltmeter Gauge

(Volt reading on W-U Lug)

Figure 20. AC Ammeter

(Amp reading on U lug)

The

NOTE

ammeter

show a reading when the

Output Terminal Lugs

gauge will only

are

connected to a load and in use.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 45

DCA-220SSJ — OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the

Voltage Change-Over Board Voltage Regulator Control Knob

and the adjustment of the

Figure 23. Voltage Regulator Knob

Remember the voltage change-over board determines the

range

of the output voltage and can be configured in two different positions that provide 6 different output voltages at 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

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 21 .

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 21.

Figure 21. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 22.

1Ø-139V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 21.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

Figure 24. UVWO Terminal Lugs

1Ø-240V Connections

Figure 22. UVWO Terminal Lugs

3Ø-240V Connections

3. Turn the voltage regulator knob (Figure 23) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

PAGE 46 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

Figure 25. UVWO Terminal Lugs

1Ø-139V Connections

DCA-220SSJ — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 26. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate

must

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 26.

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

be used.

Figure 26. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 26.

Figure 28. UVWO Terminal Lugs

1Ø-480V Connections

NOTE

Figure 27. UVWO Terminal Lugs

3Ø-480V Connections

ALWAYS make sure that the

connections to the UVWO terminals are The possibility of arcing exists, that could cause a fire.

secure

2. Connect the load wires to the UVWO terminals as shown in Figure 29.

Figure 29. UVWO Terminal Lugs

1Ø-277V Connections

and tight.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 47

DCA-220SSJ — PRE-SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 600 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

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.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 30. Engine Oil Dipstick

This generator has an internal fuel tank located inside the

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 of 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

■■

■

API Service Classification CC/SF

■■

trailer frame and may also be equipped with an environmental fuel tank (Figure 31). fresh

#2 diesel fuel.

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.

hot

engine can cause a

ALWAYS

fill the fuel tanks with clean

fire

explosion

DO NOT fill the fuel tanks beyond their

Figure 31. Internal Fuel Tank System

PAGE 48 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — PRE-SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 32).

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 33).

Figure 33. Fueling the Generator

Figure 32. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

3. NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 34).

when

Figure 34. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 35).

Figure 35. Fuel Expansion

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 49

DCA-220SSJ — PRE-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

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

WARNING - BURN HAZARDS

Air Cleaner

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

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

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove

damage and wear and adjust it in accordance with the John

Deere Engine Owner's Manual.

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 "H" and the "L" markings.

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.

battery terminal disconnected.

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When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

Figure 36. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

PAGE 50 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — PRE-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. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery 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.

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the the MANUAL or AUTO position. ALWAYS make sure that

MPEC Control Switch

the when connecting the battery.

2. 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.

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Alternator

MPEC Control Switch

is in the OFF/RESET position

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.

is in either

CAUTION - BATTERY SERVICING SAFETY

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 37. Battery Connections

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 ( immediately.

fuel

oil

) lines are defective replace them

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 51

DCA-220SSJ — GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Before starting the engine, make sure the diagnostic

manually start the engine with the

auxiliary

switch (Figure 38) on the Diagnostic Display Panel Assembly is in the “OFF” position.

circuit breakers in the ON (closed) position.

main, GFCI

3. Make sure the the been configured for the desired output voltage.

4. Connect the load to the

terminal lugs

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).

Starting (Manual)

voltage change-over board

receptacles or

as shown in Figure 14. These load

Figure 40. Engine Enclosure Doors

the

output

has

Figure 38. Diagnostic Switch (OFF poistion)

2. Place the (Figure 39) in the OFF position prior to starting the engine.

main, G.F.C.I.,

Figure 39. Main, Aux. and GFCI

Circuit Breakers (OFF)

and

aux.

circuit breakers

1. Place the engine speed switch (Figure 41) in the “ (down) position

Figure 41. Engine Speed Switch (Low)

2. Place the

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.

MPEC Control Switch

Figure 42. MPEC Control Switch

(Manual Position)

in the MANUAL

LOW

”

PAGE 52 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR START-UP PROCEDURE (MANUAL)

When the MPEC Control switch is

NOTE

glow plugs are warmed. When the preheat lamp goes off this signals the completion of the preheating cycle and the starting of the engine.

3. If any abnormalities exists, the Warning and Emergency Stop lamps on the Engine Operating Panel will be lit.

4. Place the

OFF/RESET position.

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 Radiator Coolant).

MPEC Control Switch

placed in the manual position, preheating of the glow plugs will begin automatically and the preheat lamp

will stay lit until the

Preheat Lamp

(Figure 42) in the

8. To restart the engine due to error codes, place the

9. If the engine is running smoothly, place the engine

10.Verify that the Engine Running

11. Observe that the Warning and Emergency Stop lamps

Control Switch

speed switch (Figure 44) in the “

Figure 44. Engine Speed Switch (High)

status LED on the MPEC unit (Figure 45) is ON (lit) after the engine has been started.

on the Engine Operating Panel are OFF.

in the MANUAL position (Figure 42)

HIGH

” (up) position.

Figure 45. Engine Running LED (ON)

MPEC

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 arrow buttons indicating that there are more fault codes that need to be viewed. Use the arrow buttons to scroll to the next active fault code.

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, the 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.

13. The generator's AC-voltmeter (Figure 47) will display the 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.

Figure 46. Frequency Meter (Hz)

Figure 47. Voltmeter

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 53

DCA-220SSJ — GENERATOR START-UP PROCEDURE (MANUAL)

Figure 48. Voltage Adjust Control Knob

14. The ammeter (Figure 49) will indicate applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

15. The engine oil pressure gauge (Figure 50) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (241~448 kPa). When starting the generator

16. The (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

17. The will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

zero amps

coolant temperature gauge

tachometer gauge

with no load

Figure 49. Ammeter

(No Load)

Figure 50. Oil

Pressure Gauge

Figure 51. Coolant

Temperature Gauge

(Figure 52)

Figure 52. Engine

Tachometer Gauge

18. Place the ON position (Figure 53).

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 a load is in use.

20. The generator will run until manually stopped or an abnormal condition occurs.

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

building’s electrical system may occur without this transfer switch.

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.

NOTE

main, GFCI

Figure 53. Main, Aux. and GFCI

Circuit Breakers (ON)

, and

aux

. circuit breakers in the

Figure 54. Ammeter

(Load)

licensed

must install an

. Serious damage to the

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

isolation

in the event of

PAGE 54 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR START-UP PROCEDURE (AUTO MODE)

WARNING - AUTO MODE MAINTENANCE

When 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.

CAUTION - ENGINE SPEED SWITCH

The

Engine Speed Switch

position when running in the set the switch in the proper position can result in damage to your generator when it turns on.

NOTE

must be set to the “High”

Auto-Start

When the MPEC is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

mode. Failing to

Control Switch

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 6 in the as outlined in the

2. Place the position

3. Place the position

4. Continue operating the generator as s outlined in the

Manual Start-up

Manual

Before Starting

Manual Starting Procedure

engine speed switch

Figure 54. Engine Speed Switch (High)

MPEC Control Switch

Figure 55. MPEC Control Switch (AUTO)

procedure (start at step 5).

(Figure 54) in the HIGH

(Figure 55) in the AUTO

section .

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 55

DCA-220SSJ — GENERATOR SHUT-DOWN PROCEDURES

WARNING -

NEVER stop the engine suddenly except in an emergency.

CAUTION -

ALWAYS make sure the diagnostic switch is placed in the OFF position before attempting to shut down the generator.

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

To shutdown the generator use the following procedure:

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 “

(down) position.

SHUTTING DOWN THE GENERATOR

DIAGNOSTIC SWITCH

LOW

Emergency Shutdown Procedure

1. To shut-down the engine in the event of an emergency, push the

2. Switch the breakers to OFF position.

”

Emergency Stop Button

MAIN, GFCI

Figure 58. Emergency Stop Button

and

(Figure 58).

LOAD

(Figure 38) circuit

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

OFF/RESET position.

Figure 57. MPEC Control Switch (Off/Reset)

5. Verify that the are OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occured during operation.

MPEC Control Switch

all

status LED on the MPEC display

(Figure 57) to the

PAGE 56 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — MAINTENANCE (ENGINE)

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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.

Air 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

Service Daily

If the engine is operating in very 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

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.

indicator.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 57

dusty

if these conditions exists.

dry grass

DCA-220SSJ — 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

Engine Manual

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

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. 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.

for details.

John Deere

Flushing Out Radiator and Replacing Coolant

Open 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.

Check hoses for softening and kinks. Check clamps for signs of leakage.

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.

Tighten both cocks and replace the overflow tank. Replace with coolant as recommended by the engine

manufaturer. Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Generator Storage

cool

when flushing out

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

Replace the fuel filter cartridge with new one every 500 hours or so.

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.

Vent any air.

For longe term storage of the generator the following is recommended:

Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

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— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — MAINTENANCE (HEATER/CHARGER)

Jacket Water Heater and Internal Battery Charger 120 VAC 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

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 to apply power to jacket water heater. However, if the generator will be used in 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.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

Figure 59. DCA-220SSJBattery Charger &

Jacket Water Heater Power Connections

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 59

DCA-220SSJ — MAINTENANCE (TRAILER )

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

Whisperwatt

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

™

Generator.

8. 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.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. 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 and sequence.

13. 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 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

for lug nut tightening

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

PAGE 60 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — MAINTENANCE (TRAILER )

Brakes

Trailer brakes should be inspected the

first 200 miles

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

. If driving over rough terrain, inspect the

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 replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

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

Figure 60. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

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.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the 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

7. Replace the adjusting hole cover and lower the trailer to

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

rB.ecalperrohsinrubeR

otlluPsekarBrosekarBkaeW

ediSenO

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

tsujda

?dezalggninileka

?dedaolrevoreliarT.thgiewtcerroC

?tcerroc

erusserperiT.yllauqeseritllaetalfnI

oolstnenopmocekarB.stnenopmocecalpeR

?detacirbulmetsyS.etacirbu

?yltcerrocde

gnitoohselbuorTekarBciluardyH.51elbaT

?devoorgroderocssmurdekarB.ecalperroenihcaM

?elxaemasehtnodehctamnuseriT.serithctaM

?nekorbrotneb,es

?dnuor-fo-tuosmurdekarB.ecalpeR

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

tonrotcerrocnissenkcihtgninilekarB

?diulftcerrocrodiulfekarbhguonE

surge

push

actuator

dnaseohswenllatsnI

.sgninil

straprebburecalpeR

.diulf4todhtiwllif

” to make

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 61

DCA-220SSJ — MAINTENANCE (TRAILER)

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

leaf suspension

The (Figure 61) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

springs and associated components

Figure 61. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation 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.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

stnemeriuqeReuqroTnoisnepsuS.71elbaT

PARTS MUST ROTATE FREELY

BOLT ASSEMBLY

05-XAM03-NIM

PAGE 62 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — 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 the 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.

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 62. Wheel Lug Nuts

Tightening Sequence

NOTE

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 63

DCA-220SSJ — TRAILER WIRING DIAGRAM

Figure 63. Trailer/Towing Vehicle Wiring Diagram

PAGE 64 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR WIRING DIAGRAM

Figure 64. Generator Wiring Diagram

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 65

Figure 65. Engine Wiring Diagram

DCA-220SSJ — ENGINE WIRING DIAGRAM

PAGE 66 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — 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.

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 67

DCA-220SSJ — 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.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve )dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

?ytridpukcipci

?detarbilacebotsdeenrellortnoCenign

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

sujdA

PAGE 68 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

NOTE PAGE

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 69

DCA-220SSJ — EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. ....1 ....

3 12348 HOSE .................... A/R .. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

, #, +, %, or >) 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 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.

NOTE

without notice

WASHER, 1/4 IN. ...........

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.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

QTY. Column

Numbers Used - Item quantity can be indicated by a number,

a blank entry, or A/R. 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

symbol will be included when this item is purchased. Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

range where a particular part is used. Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

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:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

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 time of publication.

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.

PAGE 70 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

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.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-220SSJ — SUGGESTED SPARE PARTS

DCA-220SSJ WHISPER WATTGENRATOR

W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

1 ......... M4310500803 ..... HOSE, RADIATOR UPPER

1 ......... M4310500903 ..... HOSE, RADIATOR LOWER

1 ......... 060202011062 .... RADIATOR CAP

1 ......... 0845500104 ........ FUEL CAP

1 ......... 0602015230 ........ V-BELT SET, FAN

1 ......... 0602122272 ........ UNIT, OIL PRESSURE

1 ......... 0602122281 ........ SWITCH, OIL PRESSURE

1 ......... 0602123282 ........ TEMP SENSOR UNIT

1 ......... 0602123261 ........ SWITCH, TEMPERATURE SENSOR

3 ......... 0810105400 ........ FILTER, FUEL, FUEL TANK

6 ......... 0602042596 ........ FILTER, FUEL PRIMARY

6 ......... 0602042597 ........ FILTER, FUEL FINAL

6 ......... 0602041292 ........ FILTER, OIL CARTRIDGE

3 ......... 0602046617 ........ ELEMENT AIR OUTER

3 ......... 0602046618 ........ ELEMENT AIR INNER

1 ......... 0601808803 ........ CIRCUIT BREAKER 1P 20A

1 ......... 0601808804 ........ CIRCUIT BREAKER 2P 50A

2 ......... LY2DUS12VDC ... RELAY

Part number on this Suggested Spare Parts list

NOTE

may supercede/replace the P/N shown in the text pages of this book.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 71

GENERATOR ASSY.

DCA-220SSJ — GENERATOR ASSY.

PAGE 72 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C1110000002 ROTOR ASSEMBLY .................................. 1 ............. INCLUDES ITEMS W/

1-1

1-2 1-3 1-4 1-4A 0040005000 SPRING WASHER 2 1-4B 0041205000 PLAIN WASHER 2 1-5 8171070002 FAN 1 1-6 8171611003 COUPLING DISK 9 1-7 C1164200004 WASHER, COUPLING HUB 1

1-8 8171015003 BALANCING PLATE .................................. 1 ............. PURCHASE ITEM 1-11 AS A SET

1-9 0012116045 HEX. HEAD BOLT 8 1-10 0042616000 SPRING WASHER 8 1-11 0601000209 BALANCING WEIGHT KIT 1 1-12 C1112500004 BEARING FLANGE 1 1-13 0071906314 BEARING, 6314DDU C3 1 2 M4163400003 COUPLING RING 1 3 0343206120 HEX. HEAD BOLT 8 4 0043606000 SPRING WSHER 8 5 0012112040 HEX. HEAD BOLT 8 6 0042512000 SPRING WASHER 8

7 C1130100103 STATOR ASSEMBLY ................................. 1 ............. INCLUDES ITEMS W/#

7-1# 0226100420 RUBBER SEAL 1 7-2# 8171323004 CLAMPER 1 7-3# 0223300120 RUBBER SEAL 1 7-4# 8171323103 CLAMPER 1 7-5# 0221200300 RUBBER SEAL 1 7-6# 0010110035 HEX. HEAD BOLT 2 7-7# 0041210000 PLAIN WASHER 2 7-8# C1132200003 COVER 1 7-9# 0226000510 RUBBER SEAL 1 7-10# 0225000470 RUBBER SEAL 1 7-11# 0017106016 HEX. HEAD BOLT 6 7-12# 0601850144 GROMMET 1 8 C1154999992 END BRACKET 1 9 C1138000003 FIELD ASSEMBLY, EXCITER 1

0601842334 RESISTOR, 80W 100K OHM 1

0601823282 RECTIFIER, RM50TC- 24 1

0018205020 HEX. SOCKET HEAD CAP SCREW 2

FIELD ASSEMBLY 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 73

GENERATOR ASSY.

DCA-220SSJ — GENERATOR ASSY. (CONT.)

PAGE 74 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ — GENERATOR ASSY. (CONT.)

GENERATOR ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

10 0012110065 HEX. HEAD BOLT 4 10A 0042610000 SPRING WASHER 4 10B 0041210000 PLAIN WASHER 4 11 0017112045 HEX. HEAD BOLT 6 12 C1154400004 COVER, BEARING 1 13 C1154300004 GASKET, BEARING 1 14 0010106060 HEX. HEAD BOLT 4 14A 0040006000 SPRING WASHER 4 14B 0041206000 PLAIN WASHER 4 15 C1154400103 SUCTION COVER 1 16 0017106016 HEX. HEAD BOLT 8 17 0343205150 HEX. HEAD BOLT 12 18 0043605000 SPRING WASHER 12 19 C1132300114 COVER, FAN 1 20 0010106030 HEX. HEAD BOLT 1 20A 0041206000 PLAIN WASHER 1 20B 0600815000 NUT 1 21 0605000012 RUBBER SUSPENSION 2 22 0030020000 HEX. NUT 4 22A 0040020000 SPRING WASHER 4 23 0070506907 BEARING, 6907ZZ 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 75

CONTROL PANEL ASSY.

DCA-220SSJ— CONTROL PANEL ASSY.

PAGE 76 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4223000303 CONTROL PANEL 1 2 M4223000404 CONTROL PANEL 1 2-1 0222100100 RUBBER SEAL 2 2-2 0222100165 RUBBER SEAL 2 3 0605011211 PIN 2 4 0016908035 HEX. HEAD BOLT 4 5 0601807642 FREQUENCY METER, 45 ~65HZ 240V 1 6 0601808992 AC AMMETER, 0~400A 0~800A 1 7 0601801040 CHANGE- OVER SWITCH, AMMETER 1 8 0601800275 AC VOLTMETER, 0~600V 1 9 0601801041 CHANGE- OVER SWITCH, VOLTMETER 1 10 0601840073 RHEOSTAT (VR), 2W 1K OHM 1 11 0601840121 KNOB 1 12 0602202593 CONTROLLER, ECU 1 13 0027104035 MACHINE SCREW 2 13A 0207004000 HEX. NUT 2 14 0601831340 SWITCH 1 15 0601831395 ENGINE SPEED SWITCH 1 16 0602120096 TACHOMETER 1 17 0602122098 OIL PRESSURE GAUGE 1 18 0602122272 OIL PRESSURE UNIT 1 19 0602123092 WATER TEMPERATURE GAUGE 1 20 0602123263 WATER TEMPERATURE UNIT 1 21 0602121081 CHARGING AMMETER 1 22 0602125090 FUEL GAUGE 1 23 0602103092 ALARM LAMP 3 23A 0601810245 BULB, DC 18V 3 24 0601810160 PANEL LIGHT, DC 12V 1 24A 0601810213 BULB 1 25 0207004000 HEX NUT 2 26 0601831330 PANEL LIGHT SWITCH 1 27 0601831557 EMERGENCY STOP BUTTON 1 28 M9220100004 SET SCREW 2 28A 0080200007 SNAP RING 2 29 M4246700304 WIRE HARNESS, GENERATOR 1 30 M4357200102 WIRE HARNESS, ENGINE

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 77

CONTROL BOX ASSY.

DCA-220SSJ— CONTROL BOX ASSY.

PAGE 78 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4213000102 CONTROL BOX 1 2 0601809667 CURRENT TRANSFORMER, 400/5A 3 3 0027106016 MACHINE SCREW 6 4 0601870422 CIRCUIT BREAKER, 600A 1 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 M4276200004 TERMINAL PLATE 3 10 M4276300004 CHANGE- OVER PLATE 6 11 M4276100004 TIE BOLT 13 12 M9220100104 TIE BOLT 13 13 0040010000 WASHER, LOCK 26 14 0041410000 WASHER, FLAT 26 15 0016908030 HEX. HEAD BOLT 4 16 0601820625 AUTOMATIC VOLTAGE REGULATOR 1 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 25 0601813977 RECEPTACLE 1 25A 0601812891 DUST CAP 1 25B 0601812890 STRAIN RELIEF 1 26 M4270500003 SET PANEL, ELECTRIC PARTS 1 27 0016908020 HEX HEAD BOLT 4 28 0602202592 STARTER RELAY 1 29 0027106016 MACHINE SCREW 2

30 LY2DUS12VDC RELAY ....................................................................... 1.......... REPLACES P/N 0601827656

30A PTF08A BASE......................................................................... 1 .......... REPLACES P/N 0601823109

30B PYCA1 CLIP, .......................................................................... 2 .......... REPLACES P/N 0601824400

31 0027104020 MACHINE SCREW 2

32 0601821370 RECTIFIER, DE45 ..................................................... 2.......... REPLACES P/N 0601823240

33 0027104020 MACHINE SCREW 2 34 M4260600404 BRACKET, RESISTOR UNIT 1 35 0016906016 HEX HEAD BOLT 2 36 M4266600004 RESISTOR UNIT 1

37 020106050 HEX NUT ................................................................... 1 .......... REPLACES P/N 0030006000

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 79

CONTROL BOX ASSY. (CONT.)

DCA-220SSJ— CONTROL BOX ASSY. (CONT)

PAGE 80 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— CONTROL BOX ASSY. (CONT)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

38 0027106020 MACHINE SCREW 1 39 0601802218 FUSE HOLDER, 3P 1 39A 0601806653 FUSE (RIGHT SIDE) 20A 1 39B 0601802149 FUSE ( CENTER) 10A 1 40 0027103020 MACHINE SCREW 2 41 0601815154 TERMINAL BLOCK 1 42 0027104016 MACHINE SCREW 2 43 3871824004 CONTROL PANEL STOPPER 1 44 0041206000 WASHER, FLAT 1 45 0605010502 SNAP PIN 1 46 M4213500104 CONTROL BOX COVER 1 47 0016908020 HEX HEAD BOLT 8 48 M4213400104 CONTROL BOX BACK PANEL 1 49 0016908020 HEX HEAD BOLT 8 50 0226900300 EDGING 1 51 0226900215 EDGING 1 52 0017110040 HEX HEAD BOLT 3 52A 0207010000 HEX NUT 3 53 0016908020 HEX HEAD BOLT 8 54 0016908020 HEX HEAD BOLT 7

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 81

ENGINE AND RADIATOR ASSY.

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

PAGE 82 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

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 ........... 1 ......... RE504836

1-2 0602042596 PRIMARY FUEL FILTER CARTRIDGE ............ 1 ......... RE529643

1-3 0602042597 FINAL FUEL FILTER CARTRIDGE .................. 1 ......... RE522878

2 0602060015 BLOWER FAN .................................................. 1 ......... 4735-42599-02

3 0602061003 FAN SPACER ................................................... 1 ......... R81876

4 0012110110 HEX HEAD BOLT 4 5 0042510000 WASHER, LOCK 4 6 M3303200404 ENGINE FOOT 2 7 0010312030 HEX HEAD BOLT 6 8 0042512000 WASHER, LOCK 4 9 0605000011 RUBBER SUSPENSION 2 10 0030016000 HEX NUT 4 11 0040016000 WASHER, LOCK 4 12 M4923200014 RADIATOR 1 12A M4493601304 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 17A M4493601504 ACOUSTIC SHEET 1 18 0016908020 HEX HEAD BOLT 16 19 M4310600304 RUBBER SHEET 2 20 0010112060 HEX HEAD BOLT 4 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 26 M4923200044 INTER COOLER 1 27 M4310201304 BRACKET, INTER COOLER 1 27A M4493601604 ACOUSTIC SHEET 1 28 M4310201404 BRACKET, INTER COOLER 1 28A M4493601604 ACOUSTIC SHEET 1 29 0010110040 HEX HEAD BOLT 4 29A 0030010000 HEX NUT 4 29B 0040010000 WASHER, LOCK 4 29C 0041210000 WASHER, FLAT 8 30 0016910025 HEX HEAD BOLT 4 31 M4310301103 FAN SHROUD 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 83

ENGINE AND RADIATOR ASSY.

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

PAGE 84 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

32 M4310301203 FAN SHROUD 1

M4493601204 ACOUSTIC SHEET 1 33 0016908020 HEX HEAD BOLT 6 34 0016908020 HEX HEAD BOLT 4 35 M4310300903 FAN GUARD 1 36 M4310301003 FAN GUARD 1 37 0016908020 HEX HEAD BOLT 11 38 M4310300403 FAN GUARD 1 39 0016908020 HEX HEAD BOLT 8 40 M4310500803 RADIATOR HOSE, UPPER 1 41 M4310500903 RADIATOR HOSE, LOWER 1 42 0605515143 HOSE BAND 1 43 0605515142 HOSE BAND 3 44 M4310401004 INTER COOLER PIPE 1 45 M4310501303 INTER COOLER HOSE 1 46 M4310501003 INTER COOLER HOSE 1 47 M4310501403 INTER COOLER HOSE 1 48 0605515207 HOSE BAND 1 49 0605515208 HOSE BAND 3 50 0605515209 HOSE BAND 3 51 M4310600404 BRACKET, INTER COOLER PIPE 1 52 0016908020 HEX HEAD BOLT 2 53 0602326063 U BOLT 1 54 0602046538 AIR CLEANER 1

54A 0602046617 OUTER ELEMENT, AIR CLEANER ................ 1 ........... P812363

54B 0602046618 INNER ELEMENT, AIR CLEANER .................. 1........... P838813

55 0602040690 INDICATOR, AIR CLEANER 1 56 0602040559 BAND, AIR CLEANER 2 57 0016908020 HEX HEAD BOLT 4 58 0207008000 HEX NUT 4 59 M4373200304 BRACKET, AIR CLEANER 1 60 0016908020 HEX HEAD BOLT 4 61 M4383000104 PIPE, AIR CLEANER 1 62 0602040365 90 DEGREE ELBOW 1 63 0605515260 HOSE BAND 3 64 0602022580 ADAPTER 1 65 0602022561 90 DEGREE ELBOW 1 66 0603306590 CONNECTOR 1 67 0603300285 ROCKNUT 1 68 0605511395 VALVE 1 69 0603306395 HOSE JOINT 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 85

ENGINE AND RADIATOR ASSY.

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

PAGE 86 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

70 0602021070 CAP 1 71 0269200660 DRAIN HOSE 1 72 0802081003 RESERVE TANK 1 73 0602010900 RESERVE TANK CAP 1 74 M4316100103 RESERVE TANK BRACKET 1 75 0016910025 HEX HEAD BOLT 2 76 0199901500 HOSE 1 77 0193601600 HOSE 1 78 0193600700 HOSE 1 79 0605515106 HOSE BAND 3 80 0191601700 BLOWBY HOSE 1 82 M4483600003 HOSE GUIDE 1 83 0016908020 HEX HEAD BOLT 2 84 0602017090 DRAIN VALVE 1 85 0602042601 LEAK OFF LINE 1 86 0017110020 HEX HEAD BOLT 1 86A 0040510000 TOOTHED WASHER 1 87 0602220911 CLAMP 1 88 0602220910 CLAMP 1 89 0602202452 ENGINE WIRE HARNESS 1 90 0602015230 FAN BELT 1

91 813NLU0000T COOLANT LEVEL SWITCH ............................. 1 .......... REPLACES P/N 0602123290

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 87

OUTPUT TERMINAL ASSY.

DCA-220SSJ— OUTPUT TERMINAL ASSY.

PAGE 88 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4230700003 TERMINAL BOARD 1 2 M9220100304 OUTPUT TERMINAL BOLT 8 3 0801830804 TIE BOLT 8 4 0039316000 HEX. NUT 16 5 0040016000 SPRING WASHER 24 6 0041416000 PLAIN WASHER 32 7 3461860504 TERMINAL PLATE 3 8 0019208040 HEX. HEAD BOLT 5 9 M4236100403 TERMINAL COVER 1 10 M4236100504 OUTPUT WINDOW 1 11 0605010040 HINGE 2 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX NUT 4 12B 0041203000 WASHER, FLAT 4 13 0027103015 MACHINE SCREW 4 13A 0030003000 HEX NUT 4 14 M9220100804 SET SCREW 2 14A 0040006000 SPRING WASHER 2 14B 0042806000 PLAIN WASHER 2 14C 0080200005 RETAINING RING 2 15 0019206015 HEX HEAD BOLT 4 16 M4236400004 OUTLET CABLE COVER 1 17 M4236400104 OUTLET CABLE COVER SUPPORTER 1 18 0019206015 HEX HEAD BOLT 8 19 0601815194 TERMINAL BLOCK 1 20 0025304015 MACHINE SCREW 2 21 0601850275 GROMMET 1 22 0601851780 GROMMET 2 23 0601808803 CIRCUIT BREAKER, 1P 20A 2 24 0601808804 CIRCUIT BREAKER, 2P 50A 3 25 C3261600704 CIRCUIT BREAKER BRACKET 1 25-1 0222100150 RUBBER CUSHION 1 26 0019206020 HEX HEAD BOLT 2 27 0601812598 RECEPTACLE, GF-530EM 20A 2 28 0601812565 RECEPTACLE, CS6369 50A 3 29 0025304015 MACHINE SCREW 10 29A 0207004000 HEX NUT 10 30 M4236400204 COVER 1 31 0019206015 HEX HEAD BOLT 8 32 M4236100303 TERMINAL COVER 1 33 0010112045 HEX HEAD BOLT 2 34 0041212000 PLAIN WASHER 2 35 0805009804 STAY RUBBER 2 36 0030012000 HEX NUT 2 37 0605011505 STAY 1 38 0025305015 HEX HEAD BOLT 4 39 M4236100604 COVER 1 40 M4236400304 BRACKET 1 41 0019206015 HEX HEAD BOLT 2

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 89

BATTERY ASSY.

DCA-220SSJ— BATTERY ASSY.

PAGE 90 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0168614551 BATTERY, 145G51 1 2 C9109100604 BATTERY SHEET 1 3 0805000904 BATTERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 SPRING WASHER 2 7 0041608000 PLAIN WASHER 2 8 C1346600004 BATTERY CABLE 1 9 C1346600104 BATTERY CABLE 1

10 EARTH CABLE ......................................................... 1 .............. MAKE LOCALLY

11 0347010003 HEX HEAD BOLT 2 12 0208110000 HEX NUT 2 13 0845040414 TERMINAL CAP (+) 1 14 0845041304 TERMINAL CAP (-) 1 15 0017116030 HEX HEAD BOLT 1 16 0040516000 TOOTHED WASHER 1 17 0040520000 TOOTHED WASHER 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 91

MUFFLER ASSY.

DCA-220SSJ— MUFFLER ASSY.

PAGE 92 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— MUFFLER ASSY.

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 BOLT 4 6A 0040012000 SPRING WASHER 4 6B 0041212000 PLAIN WASHER 4 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— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 93

FUEL TANK ASSY.

DCA-220SSJ— FUEL TANK ASSY.

PAGE 94 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C1363001403 FUEL TANK 1 1-1 0845500104 CAP, FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 2 0605501092 FUEL GAUGE SENDER 1 2A 0605516090 GASKET 1 3 0022905015 MACHINE SCREW 5 4 M4363200104 TANK BAND 2 5 0805003414 SUPPORTER SHEET 4 6 0016908020 HEX HEAD BOLT 2 7 0207308000 HEX NUT 2 8 0222100120 RUBBER SHEET 2 9 0222100180 RUBBER SHEET 2 10 0130206000 STREET ELBOW, 1/2” 1 11 8085512104 LONG NIPPLE 1 12 0603325011 VALVE,1/2” 1 13 0132006000 PLUG, 1/2” 1 14 0191302200 SUCTION HOSE 1 15 0191302800 RETURN HOSE 1 16 0605515109 HOSE BAND 4

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 95

ENCLOSURE ASSY.

DCA-220SSJ— ENCLOSURE ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 96 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C1413004402 BASE 1 2 M1413400404 COVER 1 3 0019208020 HEX. HEAD BOLT 4 4 M4423000302 FRONT FRAME 1 4A M4493102503 ACOUSTIC SHEET 1 5 M4423000402 FRONT FRAME 1 5A M4493102503 ACOUSTIC SHEET 1 6 0016908020 HEX. HEAD BOLT 10 7 0019210035 HEX. HEAD BOLT 8 8 M4423200304 COVER, FRONT FRAME 1 8A M4493102704 ACOUSTIC SHEET 1 9 0019208020 HEX. HEAD BOLT 6 10 M4423200403 OVER COVER, FRONT FRAME 1 11 0019208020 HEX. HEAD BOLT 14 12 M4423300004 DISCHARGE GUIDE 1 12A M4493601404 ACUSTIC SHEET 1 13 M4423300104 DISCHARGE GUIDE 1 13A M4493601404 ACOUSTIC SHEET 1 14 0019206020 HEX. HEAD BOLT 12 15 M4423200204 FRONT FRAME COVER 1 15A M4493102604 ACOUSTIC SHEET 1 16 0019208020 HEX. HEAD BOLT 10 17 M4433000102 CENTER FRAME 1 17A M4493200104 ACOUSTIC SHEET 1 18 0010114050 HEX HEAD BOLT 4 18A 0030014000 HEX NUT 4 18B 0040014000 SPRING WASHER 4 18C 0041214000 PLAIN WASHER 8 19 0010120045 HEX HEAD BOLT 4 19A 0030020000 HEX NUT 4 19B 0040020000 SPRING WASHER 4 19C 0041220000 PLAIN WASHER 8 20 M4443000102 REAR FRAME 1 20A M4493301904 ACOUSTIC SHEET 1 21 0019210035 HEX HEAD BOLT 4 22 M4443300204 COVER, REAR FRAME 1 22A M4493302004 ACOUSTIC SHEET 1

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 97

ENCLOSURE ASSY. (CONT.)

DCA-220SSJ— ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 98 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

DCA-220SSJ— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

24 0207306000 HEX. NUT 11 25 0019208020 HEX. HEAD BOLT 10 26 M4443200403 DOOR, REAR FRAME 1 27 M4443600004 WINDOW PLATE 1 28 0207306000 HEX. NUT 8 28A 0041206000 PLAIN WASHER 8 29 B9114000002 DOOR HANDLE 1 30 0021806016 MACHINE SCREW 4 30A 0030006000 HEX. NUT 4 31 0845047104 HINGE 2 31A 0845045004 WASHER 2 32 0019208020 HEX. HEAD BOLT 3 33 0845031504 BLIND PLUG 2 34 0600800320 MANUAL PAK 1 35 0027106016 MACHINE SCREW 4 36 M4463100202 ROOF PANEL 1 36A M4493501003 ACOUSTIC SHEET 1 37 M3310600004 COVER 1 38 0019208020 HEX HEAD BOLT 4 39 M4463200202 ROOF PANEL 1 39A M4493501903 ACOUSTIC SHEET 1 40 M4463200403 REAR ROOF DUCT 1 40A M4493502004 ACOUSTIC SHEET 1 41 0016908020 HEX HEAD BOLT 10 42 M4463400003 DUCT COVER 1 43 0016908020 HEX HEAD BOLT 7 44 M4463200304 COVER 2 45 0016906020 HEX HEAD BOLT 12 46 M4465300204 GUTTER 2 47 0019206016 HEX HEAD BOLT 8 48 0019208020 HEX. HEAD BOLT 32 49 M4453200102 SPLASHER PANEL 1 49A M4493404604 ACOUSTICSHEET 1 50 0019108065 HEX. HEAD BOLT 6 50A 0042308000 SPRING WASHER 6 50B 0042408000 PLAIN WASHER 6

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 99

ENCLOSURE ASSY. (CONT.)

DCA-220SSJ— ENCLOSURE ASSY. (CONT.)

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 100 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

Multiquip DCA-220SSJ User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual