Multiquip DCA-220SSK User Manual

PARTS AND OPERATION MANUAL

Table of Contents

PARTS AND OPERATION MANUAL

MQ POWER

DCA-220SSK

WHISPERWATT

GENERATOR

(Standard)

Up to S/N3696500 S/N3699150 to S/N3699619 S/N3699637 to S/N3703349 S/N3703364 to S/N3703853

S/N3703869~

(For serial numbers not listed, please refer to Sunbelt or GEER manuals)

Revision #3 (06/05/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 F AX: 310-537-3927 F AX: 310-638-8046 E-mail:mq@multiquip.com

SERVICE DEPARTMENT:

• www:multiquip.com

Table of Contents

PAGE 2 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

HERE'S HOW TO GET HELP

Table of Contents

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

SER VICE DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

WARRANTY DEPARTMENT

800/835-2551 or 310/537-3700 FAX: 310/638-8046

MAIN

800/421-1244 or 310/537-3700 FAX: 310 - 537-3927

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ........................................3

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

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

Rules for Safe Operation ......................................6- 9

Towing Safety Precaution .....................................10

Trailer Safety Guidelines.......................................11-17

T railer Wiring Diagram ...........................................18

Electrical Brake Troubleshooting...........................19

Hydraulic Brak e Troubleshooting...........................20

Operation and Safety Decals................................21-22

DCA 220 Specifications .......................................23

General Information ..............................................24-26

Major Components ...............................................27

Dimensions...........................................................28-29

Control Panel Descriptions ...................................30-31

Engine Operating P anel Descriptions ................... 32-33

Output T erminal Overview.....................................34-41

Installation ............................................................42-43

Pre Setup .............................................................44-47

Load Application ...................................................48

Generator Start-up Procedure (Manual)................49-52

Generator Start-up Procedure (Auto)....................53

Generator Shut-Down Procedure ..........................54

Maintenance .........................................................56-59

Generator Wiring Diagram .....................................60

Engine Wiring Diagrams ....................................... 62-63

Engine T roubleshooting .........................................64-65

Generator/Engine T roubleshooting ........................66

MPEC T roubleshooting .........................................67

Explanation of Code in Remarks Column .............68

Serial Numbers Pertaining to Unit ........................68

Suggested Spare Parts ........................................69

NOTE

DCA-220SSK GENERA TOR

Generator Assembly-Up to S/N1337562...............70-73

Generator Assembly-S/N1337563~ ......................74-77

Control Box and Panel Assembly-

Up to S/N1337562 ................................................78-81

Control Box and P anel (Optional)-

Up to S/N1337562 ................................................82-85

Control Panel Assemb ly-S/N1337563~.................86-87

Control Box Assembly-S/N1337563~ ...................88-91

Engine & Radiator Assembly-Up to S/N1337562..92-95 Engine & Radiator Assembly-

S/N1337563 to 3690734 .......................................96-99

Engine & Radiator Assembly-S/N3690735~ .........100-103

Engine Operating and Output Terminal Assembly-

Up to S/N1337562 ................................................104-109

Engine Operating Panel Assembly (Opt. Parts,

with Slow-Down)-Up to S/N1337562 .....................110-115

Engine Operating P anel Assembly-S/N1337563~ 116-119 Output T erminal Panel Assembly-

S/N1337563 to 3690734 .......................................120-121

Output T erminal Panel Assembly-S/N3690735~ ...122-123

Actuator-S/N3690735~ .........................................124-125

Battery Assembly ................................................. 126-127

Muffler Assembly ................................................. 128-129

Fuel Tank Assembly-Up to S/N1337562 ...............130-131

Fuel T ank Assembly-S/N1337563~.......................132-133

Enclosure Assembly-Up to S/N1337562 ..............134-139

Enclosure Assembly-S/N1337563~......................140-145

Rubber Seal Assembly-Up to S/N1337562........... 146-147

Rubber Seal Assembly-S/N1337563~ ..................148-149

Automatic Oil Feeder Assembly (Opt. Parts)-

Up to S/N1337562 ................................................150-151

Control Box Assembly Remote (Opt. Parts)-

Up to S/N1337562 ................................................152-153

Name Plate And Decals .......................................154-157

Specification and part number are subject to

Terms and Condition of Sale — Parts .................. 158

change without notice.

PAGE 4 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

PARTS ORDERING PROCEDURES

Table of Contents

■■

■ 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:

■■

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)* Airborne Express*

•

Tr uck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered Additional Discount

1-9 items 3% 10+ items** 5%

Get special freight allowances when you order 10 or more line items via FAX!**

■■

■

UPS Ground Service at no charge for freight

■■

■

PS Third Day Service at one-half of actual freight cost

■■

No other allowances on freight shipped by an y other carrier. **Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

Now! Direct TOLL-FREE access

Extra Fax Discount for

Domestic USA Dealers

Only

UPS

Special

For faxed orders only

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE* Fax order discount and UPS special programs revised June 1, 1995

800/6-PARTS-7 • 800-672-7877

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 5

CAUTION:

Table of Contents

RULES FOR SAFE OPERATION

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained

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

The following safety guidelines should always be used when operating the DCA-220SSK portable generator:

GENERAL SAFETY

■

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

■

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.

■

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 adding fuel or performing service and maintenance functions. Contact with burns.

■

The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

CAUTION

■

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

hot

components can cause serious

Always refuel in a well-ventilated area, away from sparks and open flames.

■

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

■

NEVER use accessories or attachments, which are not recommended by MQ P ower f or 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.

■

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

■

Always check the machine for loosened threads or bolts before starting.

PAGE 6 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

■

Always use extreme when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

■

NEVER operate the generator in an

explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

or even death.

Topping-off to filler por t is dangerous, as it tends to spill fuel.

CAUTION

bodily harm

RULES FOR SAFE OPERATION

Table of Contents

CAUTION

■

NEVER touch output terminals dur ing operation. This is extremely dangerous. contact with the output terminals.

CAUTION

■

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 stop the machine when

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain plug

3. Engine Oil Drain Plug - Removing the engine oil drain

■

DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

engine is hot due to high pressure, will result in boiling water to gush out of the radiator, therefore causing severe scalding to any persons in the general area of the generator .

while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

CAUTION

Never use damaged or worn cables when

connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 7

RULES FOR SAFE OPERATION

Table of Contents

Battery

CAUTION

The battery contains acids that can cause injury to the eyes and skin. To avoid ey e irritation, alwa ys wear safety glasses . Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

1. DO NOT drop the battery. There is the possibility of risk that the battery may explode.

2. 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 .

Never over fill the battery with water above the upper limit.

NEVER Run engine without air filter. Severe engine damage may occur.

Always service air cleaner frequently to prevent carburetor malfunction.

Always disconnect the battery before performing service on the generator .

Always be sure the operator is familiar with proper safety precautions and operations techniques before using generator .

Always store equipment properly when not in use. Equipment should be stored in a clean, dry location out of the reach of children.

DO NOT lea ve the generator running in the manual mode unattended.

DO NOT allow unauthorized people to operate this equipment.

Always read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

Refer to the technical questions or information.

Komatsu Engine Owner's Man ual

for engine

3. Always keep the battery charged. If the battery is not charged a buildup of combustib le gas will occur.

4. Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.

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

7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water , then contact the nearest doctor or hospital, and seek medical attention.

clothing or skin

, rinse skin or clothing

Loading and Unloading (Crane)

Before lifting, make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.

Always drain fuel prior to lifting.

Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator.

NEVER lift the machine while the engine is running.

Use adequate lifting cable (wire or rope) of sufficient strength.

When lifting the generator, always use the balanced center-point suspension hook and lift straight upwards.

NEVER allow any person or animal to stand underneath the machine while lifting.

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

PAGE 8 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

RULES FOR SAFE OPERATION

Table of Contents

Transporting

■

Always shutdo wn engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances or bad roads.

■

Alwa ys tie-down the generator during transportation by securing the generator .

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. See page 10 for basic towing procedures.

Emergencies

■

Always know the location of the nearest

extinguisher

nearest telephone. Also know the phone numbers of the nearest

and

first aid kit

ambulance, doctor

. Know the location of the

and

fire department

fire

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

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. Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

DO NOT use plastic containers to dispose of hazardous waste.

DO NOT pour w aste, oil, coolant or fuel directly onto the ground, down a drain or into any water source

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 9

DCA-220SSK — TOWING

Table of Contents

Towing Safety Precautions

CAUTION :

Check with your county or state safety towing regulations department before towing your generator .

To reduce the possibility of an accident while transporting the generator on public roads, always make sure that the trailer (Figure 1) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the tr ailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling f or wear . NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS attach trailer's saf ety chain to bumper of towing vehicle.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly .

■

Remember the maximum speed unless otherwise posted for highway towing is 45 MPH. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.

■

Place

rolling,

■

Place prevent

■

Use the trailer's hand winch to adjust the height of the trailer , then insert locking pin to lock wheel stand in place , while parked.

■

Av oid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when tr ansporting.

chocked blocks

while parked.

support b locks

tipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

■

ALWAYS mak e sure the trailer is equipped with a "Safety Chain".

■

DO NOT transport generator with fuel in tank.

PAGE 10 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 1. Generator with Trailer

DCA-220SSK — TRAILER-SAFETY GUIDELINES

Table of Contents

CAUTION:

ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury .

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:

Brakes

Tires

Lug Nut T orquing

Suspension

Electrical

Brake T roubleshooting T ables

Use the following definitions reading Table 1.

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, h ydraulic-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 - This measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to fender.

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

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

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 (lay ers) 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 are 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 4 and Figure 5 or lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3). Please not 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 shock transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

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.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 11

DCA-220SSK — TRAILER-SPECIFICATIONS

Table of Contents

snoitacificepS.1elbaT

LEDOM NOITACILPPA LEUF

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TBS52-RLRT 52-ACDONONSBL0992"021"66.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

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FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

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PAGE 12 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER-SPECIFICATIONS

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 13

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

Brakes

If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet. Listed below are some of the advantages that electric brakes have over hydraulic brakes:

Brake system can be manually adjusted to provide the

corrected braking capability for varying road and load conditions

Brake system can be modulated to provide more or less

braking force, thus easing the brake load on the towing vehicle

Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the tr ailer’s brakes are actuated

Brake system can provide an independent emergency

brake system

In order to properly synchronize the towing vehicle’s braking to the trailer’s braking system, can only be accomplished by road testing. Brake lockup, grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required.

Electric 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 scre wdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

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

8. Repeat steps 1 through 6 on the remaining brakes.

PAGE 14 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These bra kes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage. Figure 3 below displays the major hydraulic/air/surge brake

components that will require inspection and maintenance. Inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 15

DCA-220SSK — TRAILER SAFETY GUIDELINES

Table of Contents

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.

CAUTION:

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.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold bef ore operation DO NO T bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear . Table 2 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Suspension

The leaf suspension springs and associated components (Figure 4) 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 . T orqued suspension components as detailed in Table 3.

CAUTION:

AL WA YS w ear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

NOTE

Figure 4. Major Suspension Components

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Table of Contents

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-220SSK — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FI T ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAI N NUT

BOLT ASSEMBLY

05-XAM03-NIM

Lug Nut Tor que 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. Star t all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 5. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 4.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

"2152-0204-5356-05

"3152-0204-5356-05

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"5152-0206-05021-09

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NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 17

DCA-220SSK — TRAILER-WIRING DIAGRAM

Table of Contents

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 19

DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING

Table of Contents

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PAGE 20 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK —OPERATION AND SAFETY DECALS

Table of Contents

Machine Safety Decals

The DCA-220SSK generator is equipped with a number of saf ety decals. These decals are pro vided for operator saf ety and maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 21

DCA-220SSK —OPERATION AND SAFETY DECALS

Table of Contents

PAGE 22 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK SPECIFICATIONS

Table of Contents

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DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 23

DCA-220SSK — GENERAL INFORMATION

Table of Contents

DCA-220SSK F AMILIARIZATION Generator

The MQ Po wer Model DCA-220SSK is a 176 kW 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 Control Panel

The “Engine Control Panel” is provided with the f ollowing:

Tachometer

Water T emperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine W arning Lamp Module

Engine Speed Switch

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Generator Control Panel

The “Generator Control P anel” is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

V oltmeter Change-Ov er Switch

Panel Light

Panel Light Switch

Pilot Lamp

Microprocessor Engine Control Unit

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 600 amps

Over-Current Relay

High Idle Adjust Trimmer

generator

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 600 amps

Over-Current Relay

High Idle Adjust Trimmer

Open Delta Excitation System

The DCA-220SSK generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four leads: A, B, C and D. During light loads, the power to the from the leads parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load.

Microprocessor Controlled Alarm System

The DCA-220SSK generator is equipped with various alarms and LED status indicators. These alarms and status indicators are provided to add safety to the generator when operating under normal conditions. The DCA-220SSK generator is designed to shutdown in the event of low oil, high coolant temperature, low battery and other operation conditions that may cause severe damage to the generator.

Open-Delta

" excitation system. The open delta

Automatic V oltage Regulator

fixed ceiling

(A VR) is supplied

" and responds

Output T erminal Panel

The “Output T erminal P anel” is provided with the f ollowing:

Three 240/139V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 265V @65 amps

2 Load GFCI Circuit Breakers 265V@ 20amps

PAGE 24 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — GENERAL INFORMATION (OPTIONS)

Table of Contents

Engine The DCA-220SSK is powered by a 4 cycle, water cooled,

diesel

turbocharged K OMA TSU Model SA6D125E-2 This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 16 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-220SSK generator are addressed on the following pages.

Electronic Governor System

The electronic governor system replaces the standard mechanical governor system. The frequency regulation improves from ±3.0% regulation with the mechanical governor to ±0.25% regulation with the electronic governor system.

Jacket Water Heater

The jacket water heater is a 1500-watt heater designed to keep the coolant warm in the engine block for fast starts and load acceptance. The heater is thermostatically controlled and once an acceptable engine temperature is achieved it will cycle on and off, operating only about 1/3 of the time, which makes it more efficient than the direct block type heater. It is designed to keep the engine coolant between 100 and 120 degrees F ahrenheit.

engine.

CAUTION

Battery Charger

The battery charger will operate in a ‘BOOST’ mode until the battery’s current acceptance falls to 70% of the charger’s rating. The charger will then go into a ‘FLOAT’ mode, where it discharges a lower voltage until an AC failure, or the battery is discharged.

ALWAYS unplug the jacket water heater

before servicing.

Under normal conditions, 20 to 15 minutes is required to raise the engine temperature of a cold engine to 100 degrees Fahrenheit.

NOTE: The jacket water heater can be

serviced if not functioning properly.

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 25

DCA-220SSK — WATER SEP ARATOR FILTER (OPTIONAL)

Table of Contents

Water Separator Filter

The DCA-220SSK generator may be equipped with a “Water Fuel Separator". This unit is designed to prevent dirt, rust, algae, varnishes and water from entering the fuel system.

This water separator system is designed around two filters connected in parallel (Figure 6). These two filters can be configured in a variety of ways to filter water from the fuel system.

For best results it is best to have both filters active (ON) at the same time or use only one filter, and use the other filter as a reserve, that way you can use the filters alternately every time the filter element is replaced.

CAUTION

DO NOT turn the control valve while the generator is in operation. This ma y stop fuel flow to the generator if both filters are set to

the OFF position.

Figure 6. Water Separator Filter

Collection Bowl W ater Draina ge

Inspect or drain the water in the collection bowl daily. The collection bowl must be drained before contaminants reach the bottom of the turbine.

To drain the collection bowl perform the following:

1. Open the self-venting drain to evacuate contaminants with a suitable collection container in place.

2. Prime the unit by removing the filter lid and filling with clean fuel.

3. Replace the filter lid and snugly tighten the T-handle by hand only.

PAGE 26 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

DCA-220SSK — MAJOR COMPONENTS

Table of Contents

Figure 7. Major Components

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 27

DCA-220SSK — DIMENSIONS (T OP AND SIDE)

Table of Contents

PAGE 28 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 8a. Dimensions

DCA-220SSK — DIMENSIONS (FRONT AND REAR)

Table of Contents

Figure 8b. Dimensions

DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 29

DCA-220SSK — CONTROL PANEL

Table of Contents

PAGE 30 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)

Figure 9. Control Panel

+ 130 hidden pages