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Multiquip C1870300404 manual

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Table of contents for the manual

  • Page 1

    P AR TS AND OPERA TION MANUAL OPERA TION AND P AR TS MANUAL Re vision #1 (02/28/14) THIS MANU AL MUST A CCOMP ANY THE EQUIPMENT A T ALL TIMES. ® MODEL DCA220SSJ/SSJU 60HZ WHISPER W A TT™ GENERA T O R (JOHN DEERE 6068HF485 DIESEL ENGINE) P AR TS LIST NO . C1870300404 (DCA220SSJ) P AR TS LIST NO . M4870300104B (DCA220SSJU)[...]

  • Page 2

    P A GE 2 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Diesel engine exhaust and some of DCA-220SSJ/SSJU — PR OPOSITION 65 W ARNING[...]

  • Page 3

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 3 1 DCA-220SSJ/SSJU — NO TE P A GE[...]

  • Page 4

    P A GE 4 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — T ABLE OF CONTENTS MQ POWER DCA-220SSJ/SSJU MQ POWER DCA-220SSJ/SSJU MQ POWER DCA-220SSJ/SSJU MQ POWER DCA-220SSJ/SSJU MQ POWER DCA-220SSJ/SSJU WHISPER WHISPER WHISPER WHISPER WHISPER W W W W W A A A A A TT TT TT TT TT TM TM TM TM TM GENERATO[...]

  • Page 5

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 5 1 DCA-220SSJ/SSJU — P ARTS ORDERING PR OCEDURES www .multiquip .com Or dering par ts has never been easier! Choose fr om three easy options: WE A CCEPT ALL MAJOR CREDIT CARDS! When or dering par ts, please supply: ❒ Dealer Account Number ❒ Dealer Name and Address[...]

  • Page 6

    P A GE 6 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — SPECIFICA TIONS[...]

  • Page 7

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 7 1 DCA-220SSJ/SSJU — DIMENSIONS (T OP , SIDE AND FR ONT) Figure 1. Dimensions S N O I S N E M I D . 3 E L B A T e c n e r e f e R r e t t e L ) . m m ( . t f n o i s n e m i Dr e t t e L e c n e r e f e R) . m m ( . t f n o i s n e m i D A) . m m 0 4 9 ( . n i 0 0 . 7[...]

  • Page 8

    P A GE 8 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ P ow er Model DCA-220SSJ/ SSJU Whisperwatt™ Generator . Bef ore using this g enerator , ensure that the operating individual has read and[...]

  • Page 9

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 9 1 DCA-220SSJ/SSJU — SAFETY MESSA GE ALERT SYMBOLS AL W A YS place the MPEC control s witch in the OFF/RESET position when the generator is not in use. AL W A YS wear approv ed respiratory protection. AL W A YS wear approv ed eye and hearing protection. Other impor ta[...]

  • Page 10

    P A GE 10 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — R ULES FOR SAFE OPERA TION The following safety guidelines should always be used when operating the DCA-220SSJ/SSJU Whisperwatt™ A C Generator . General Safety: ■ DO NO T operate or service this equipment before reading this entire manua[...]

  • Page 11

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 11 1 DCA-220SSJ/SSJU — R ULES FOR SAFE OPERA TION POWER CORD (POWER ON) WET HANDS During operation of this generator , there exists the possibility of electrocution, electrical shock or burn, which can cause severe bodil y harm or e v en DEA TH! T o a void these hazard[...]

  • Page 12

    P A GE 12 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — R ULES FOR SAFE OPERA TION Battery Safety Use the following guidelines when handling the battery: ■ The battery contains acids that can cause injur y to the ey es and skin. T o avoid eye irritation, always wear safety glasses. ■ Use well[...]

  • Page 13

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 13 1 Emergencies ■ AL W A YS know the location of the nearest fire e xtinguisher . ■ AL W A YS know the location of the nearest and first aid kit . ■ AL W A YS kno w the location of the nearest phone or keep a phone on the job site, in case of emergencies. ■ AL W[...]

  • Page 14

    P A GE 14 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) The DCA-220SSJ/SSJU generator is equipped with a number of saf ety decals (Figures 2 & 3). These decals are provided f or operator saf ety and maintenance inf or mation. The illustration below and on the preceding page sho w the decals as they appear on the[...]

  • Page 15

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 15 1 DCA-220SSJ/SSJU — GENERA T OR DECALS Figure 3. Generator Decals (Cont inued)[...]

  • Page 16

    P A GE 16 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Figure 4. T ypical Generator Grounding Application DCA-220SSJ/SSJU — INST ALLA TION[...]

  • Page 17

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 17 1 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 [...]

  • Page 18

    P A GE 18 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — GENERAL INFORMA TION DCA-220SSJ/SSJU Whisperwatt™ Series Familiarization Generator The MQ P ower Model DCA-220SSJ/SSJU is a 176 kW generator (Figure 5) that is designed as a high quality por table (requires a trailer f or transpor t) pow e[...]

  • Page 19

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 19 1 DCA-220SSJ/SSJU — MAJOR COMPONENTS Figure 5. Major Components 4 e l b a T. s t n e n o p m o C r o j a M r o t a r e n e G . O N M E T IN O I T P I R C S E D 1y l b m e s s A l e n a P l a n i m r e T t u p t u O 2y l b m e s s A s e l c a t p e c e R t u p t u O [...]

  • Page 20

    P A GE 20 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — DIA GNOSTIC DISPLA Y 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 C[...]

  • Page 21

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 21 1 First Time Start Up 1 . When pow er is first applied to the diagnostic displa y , the “Logo” is displayed. 2 . The “W ait to Star t ” message will be display ed for engines with a pre-star tup sequence. Once the “Wait to Star t” message is no longer disp[...]

  • Page 22

    P A GE 22 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) 2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection. 3. Now that you have selected the language, touch the “Menu” button to return to the main menu displa y . Stor[...]

  • Page 23

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 23 1 First Time Start Up 1 . When pow er is first applied to the diagnostic displa y , the “Logo” is displayed. 2 . The “W ait to Star t ” message will be display ed for engines with a pre-star tup sequence. Once the “Wait to Star t” message is no longer disp[...]

  • Page 24

    P A GE 24 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) 2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection. 3. Now that you have selected the language, touch the “Menu” button to return to the main menu displa y . Stor[...]

  • Page 25

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 25 1 2 . The main menu will pop up on the displa y . Use the “Arrow Buttons” to scroll through the menu until the “Engine Configuration” menu item has been highlighted. 3. Once the “Engine Configuration” menu item has been highlighted touch the “Enter Butto[...]

  • Page 26

    P A GE 26 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) ! ! ! Indicates Auxiliary Gage Fault Indicates Fault Warning Indicates Derate or Shutdown Condition Fault 5. T ouching the “Enter Button” will redispla y the hidden f ault. T ouching the “Enter Button” once again will hide the fault and return the scree[...]

  • Page 27

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 27 1 Shut Down Codes 1 . During normal operation the single or four parameter screen will be displayed. 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” m[...]

  • Page 28

    P A GE 28 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) 3 . Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Backlight” function. 4. Use the “Arrow Buttons” to select the desired backlight intensity . 5. T ouch the “Menu Button” to retur [...]

  • Page 29

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 29 1 Select Units 1. Star ting at the single or four engine par ameter displa y touch the “Menu Button”. 2. The main menu will pop up on the displa y . Use the arrow buttons to scroll through the menu until the “Select Units” is highlighted. 3. Once the “Select[...]

  • Page 30

    P A GE 30 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) 3. Once the “Setup 1-up Display” menu icon has been highlighted touch the “Enter Button” to access the “Setup 1-up display” function. 4. Three options are available for modification of the 1-Up displa y . a). Use defaults- This option contains a set[...]

  • Page 31

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 31 1 1 1 . T ouch the “Enter Button” to deselect the selected parameter removing it from the list of parameters being displa yed on the 1-up displa y . 12. Use the “Arrow Button” to scroll and highlight the desired parameter that has not been selected f or displa[...]

  • Page 32

    P A GE 32 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) COOL 1800 RPM 0 1500 3000 TEMP ENG RPM 98% 14.2 57 PSI 1000 RPM LOAD RPM BATT VOL T ENG RPM OIL PRES Setup 4-Up Display 1. F rom the single or f our engine parameter displa y touch the “Menu Button”. 2 . The main menu will pop up on the displa y . Use the ?[...]

  • Page 33

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 33 1 9 . The parameter that is highlighted is the selected parameter for the screen. Use the “Arrow Buttons” to highlight the new parameter to be placed in the quadrant selected in the previous screen. 1 0 . T ouch the “Enter Button” to change the selected parame[...]

  • Page 34

    P A GE 34 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) 4 . T ouch “Select” to enter the “Gage Data” displa y . When “Gage Data” is selected the P ow erView will communicate with the analog gages at a fixed rate of 38.4k Band, 8 data bits, no parity check, 1 stop bits, half duplex. 5 . Use the “Arrow B[...]

  • Page 35

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 35 1 1 1 . T ouch the “Menu” button to return to “Utilities” menu. T ouch the “Menu b utton again to retur n to the “Main” menu. MODBUS SETUP 1 . Star ting at the single or four engine par ameter display , touch the “Menu Button”. 2 . The main menu will[...]

  • Page 36

    P A GE 36 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) GLOSSAR Y (T r oub leshooting inf ormation) CANBUS F AILURE Diagnostic Display has not received any CAN messages for at least 30 seconds. NO D A T A Diagnostic Displa y has not receiv ed the par ticular message being display ed for at least 5 seconds . NO T SUP[...]

  • Page 37

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 37 1 DCA-220SSJ/SSJU — GENERA T OR CONTROL P ANEL The definitions below describe the controls and functions of the DCA-220SSJ/SSJU Generator Control Panel (Figure 7). 1. Frequency Meter – Indicates the output frequency in her tz (Hz). Nor mally 60 Hz. 2. A C Ammeter [...]

  • Page 38

    P A GE 38 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Figure 8. Engine Operating Panel DCA-220SSJ/SSJU — ENGINE OPERA TING P ANEL The definitions below describe the controls and functions of the DCA-220SSJ/SSJU Engine Operating Panel (Figure 8). 1. Panel Light – Normally used in dark areas or at night time. Wh[...]

  • Page 39

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 39 1 DCA-220SSJ/SSJU — ENGINE OPERA TING P ANEL 8. Engine Speed Switch – This s witch controls the speed of the engine (low/high). 9. Pre-Heat Lamp – When lit, indicates engine is in the pre-heating mode (f or star ting during cold weather operating conditiions). W[...]

  • Page 40

    P A GE 40 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Output T erminal Familiarization The “ Output T erminal P anel ” (Figure 8) is provided with the following: ■ ■ ■ ■ ■ Three (3) 120/240V output receptacles @ 50 amp ■ ■ ■ ■ ■ Three (3) Circuit Breakers @ 50 amps ■ ■ ■ ■ ■ T wo [...]

  • Page 41

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 41 1 100 V A C GFCI Receptacles There are two 120 V A C, 20 amp GFCI (Duple x Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit break e[...]

  • Page 42

    P A GE 42 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Figure 14. Connecting Loads Connecting Loads Loads can be connected to the generator by the Ouput T erminal Lugs or the con vienience receptacles (Figure 14). Make sure to read the operation manual before attempting to connect a load to the generator . T o prot[...]

  • Page 43

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 43 1 DCA-220SSJ/SSJU — LO AD APPLICA TION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage , amperage, frequency , and voltage requirements are satisfactorily supplied by the generator for operating the equipm[...]

  • Page 44

    P A GE 44 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — GENERA T OR OUTPUTS Generator Amperage T ab les 8 and 9 descr ibe the generator’ s current output capa- bility for both 1Ø-phase and 3Ø phase applications. Generator Output V oltages A wide range of voltages are available to supply volta[...]

  • Page 45

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 45 1 Maximum Amps T ab le 10 shows the maxim um amps the generator can pro- vide. DO NO T e xceed the maximum amps as listed. How to Read the Output T erminal Gauge . The AC ammeter and AC voltmeter change-over switches on the control panel DO NO T effect the gener ator [...]

  • Page 46

    P A GE 46 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Figure 21. V oltage Change-Over Board 240V Configuration UVWO T erminal Output V oltages V arious output voltages can be obtained using the UVW O output ter minal lugs. The voltages at the terminals are de- pendent on the placement of the jumpers plates (6) on [...]

  • Page 47

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 47 1 DCA-220SSJ/SSJU — OUTPUT TERMINAL P ANEL CONNECTIONS 2. Connect the load wires to the UVWO terminals as shown in Figure 27. 3Ø-480V UVWO T erminal Output V oltages 1 . Jumper the voltage change-over board for 480V operation as shown in Figure 26. This configurati[...]

  • Page 48

    P A GE 48 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — SETUP Figure 30. Engine Oil Dipstick When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Jo[...]

  • Page 49

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 49 1 DCA-220SSJ/SSJU — SETUP Refueling Procedure: 1. Level T anks – Make sure fuel cells are le vel with the ground. F ailure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 32). Figure 32. Only Fill on Level Ground 3. NEVER over[...]

  • Page 50

    P A GE 50 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator , DO NO T remov e the radiator cap until the unit has completely cooled. See T ab le 12 f or engine, radiator , and recov er y tank coolant capacities. Make sure [...]

  • Page 51

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 51 1 DCA-220SSJ/SSJU — SETUP When connecting battery do the following: 1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANU AL or AU T O position. AL W A YS make sure that the MPEC Control Switch is in the OFF/[...]

  • Page 52

    P A GE 52 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Starting (Manual) 1. Place the engine speed s witch (Figure 41) in the “ LO W ” (down) position Figure 42. MPEC Control Switch (Manual P osition) DCA-220SSJ/SSJU — GENERA T OR ST ART -UP PR OCEDURE (MANU AL) The engine's exhaust contains harmful emis[...]

  • Page 53

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 53 1 10. V er ify that the Engine Running status LED on the MPEC unit (Figure 45) is ON (lit) after the engine has been star ted. 3 . If any abnormalities exists , the W ar ning and Emergency Stop lamps on the Engine Operating P anel will be lit. 4. Place the MPEC Contro[...]

  • Page 54

    P A GE 54 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Starting (Auto Mode) Before connecting this generator to any building’ s electrical system, a licensed electrician must install an isolation (transfer) switch . Serious damage to the building’ s electrical system may occur without this transfer switch. D AN[...]

  • Page 55

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 55 1 1. P erf or m steps 1 through 6 in the Before Starting section as outlined in the Manual Starting Procedure . 2. Place the engine speed switch (Figure 54) in the HIGH position 4. Continue operating the generator as s outlined in the Manual Start-up procedure (star t[...]

  • Page 56

    P A GE 56 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Normal Shutdown Procedure T o shutdown the gener ator use the f ollowing procedure: 1. Place both the MAIN , GFCI and LO AD circuit break ers as shown in Figure 39 to the OFF position. 2. Place the engine speed s witch (Figure 56) in the “ LO W ” (down) pos[...]

  • Page 57

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 57 1 DCA-220SSJ/SSJU — MAINTENANCE (ENGINE) Service Daily If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of pow er , excessiv e carbon b uildup in the combustion chamber and high fuel consump[...]

  • Page 58

    P A GE 58 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — MAINTENANCE (ENGINE) Generator Storage For longe term storage of the generator the following is recommended:  Fill the fuel tank completely . T reat with a fuel stabilizer if necessar y .  Completely drain the oil from the crankcase an[...]

  • Page 59

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 59 1 DCA-220SSJ/SSJU — MAINTENANCE (HEA TER/CHARGER) Figure 59. DCA-220SSJ/SSJUBattery Charger & Jac ket W ater Heater P ower Connections Jac ket W ater Heater and Internal Batter y Charger 120 V A C Input Receptacles (OPTIONAL) This generator can be optionally equ[...]

  • Page 60

    P A GE 60 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — MAINTENANCE (TRAILER ) 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 (la [...]

  • Page 61

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 61 1 DCA-220SSJ/SSJU — MAINTENANCE (TRAILER ) 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 fo[...]

  • Page 62

    P A GE 62 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) Tires/Wheels/Lug Nuts Tires and wheels are a v er y impor tant and cr itical components of the trailer . When specifying or replacing the trailer wheels it is impor tant the wheels, tires , and axle are properly matched. Tire W ear/Inflation Tire inflation pres[...]

  • Page 63

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 63 1 Figure 62. Wheel Lug Nuts Tightening Sequence DCA-220SSJ/SSJU — MAINTENANCE (TRAILER) Lug Nut T or que Requirements It is e xtremely impor tant to apply and maintain proper wheel mounting torque on the trailer . Be sure to use only the fasteners matched to the con[...]

  • Page 64

    P A GE 64 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — TRAILER WIRING DIA GRAM Figure 63. T railer/T owing V ehicle Wiring Diagram[...]

  • Page 65

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 65 1 DCA-220SSJ/SSJU — GENERA T OR WIRING DIA GRAM Figure 64. Generator Wiring Diagram[...]

  • Page 66

    P A GE 66 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — ENGINE WIRING DIA GRAM Figure 65. Engine Wiring Diagram[...]

  • Page 67

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 67 1 Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use T able 19 sho wn below f or diagnosis of the Generator . If the prob lem cannot be remedied, consult our company's business office o[...]

  • Page 68

    P A GE 68 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA-220SSJ/SSJU — TR OUBLESHOO TING (ENGINE CONTR OLLER) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use T able 20 (Engine Controller T roubleshooting) as a basic guideline f or [...]

  • Page 69

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 69 1 NO TE P A GE[...]

  • Page 70

    P A GE 70 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — EXPLANA TION OF CODE IN REMARKS COLUMN The f ollowing section e xplains the different symbols and remarks used in the P ar ts section of this manual. Use the help numbers f ound on the back page of the manual if there are any questions . SAMP[...]

  • Page 71

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 71 1 DCA220SSJ/SSJU — SUGGESTED SP ARE P ARTS DCA-220SSJ/SSJU WHISPER W A TTGENRA T OR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 T O 3 UNITS Qty . P/N Description 1 ......... M4310500803 ..... HOSE, RADIA T OR UPPER 1 ......... M4310500903 ..... HOSE, RADIA TOR LO W[...]

  • Page 72

    P A GE 72 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — GENERA T OR ASSY .[...]

  • Page 73

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 73 1 DCA220SSJ/SSJU — GENERA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C11 10000 102 R O T OR ASSEMBL Y .................................. 1 ............. INCLUDES ITEMS W/ * 1-1 * FIELD ASSEMBL Y 1 1-2 * 0601842334 R E S I S T OR, 80W 100K OHM 1 1-3 * 0[...]

  • Page 74

    P A GE 74 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU— GENERA T OR ASSY . (CONT .)[...]

  • Page 75

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 75 1 NO . P AR T NO . P AR T NAME QTY . REMARKS 10 0012110065 HEX. HEAD BOL T 4 10 A 0042610000 W A SHER, LOCK 4 10 B 0041210000 W ASHER, FLA T 4 11 0017112045 HEX. HEAD BOL T 6 12 C1154400004 CO VER, BEARING 1 13 C1154300004 GASKET , BEARING 1 14 0010106060 HEX. HEAD BO[...]

  • Page 76

    P A GE 76 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — CONTR OL P ANEL ASSY .[...]

  • Page 77

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 77 1 DCA220SSJ/SSJU— CONTR OL P ANEL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4223000303 CONTROL P ANEL 1 2 M4223000404 CONTROL P ANEL 1 2- 1 0222100100 R UBBER SEAL 2 2- 2 0222100165 R UBBER SEAL 2 3 0605011211 P I N 2 4 0016908035 HEX. HEAD BOL T ........[...]

  • Page 78

    P A GE 78 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — CONTR OL BO X ASSY .[...]

  • Page 79

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 79 1 DCA220SSJ/SSJU — CONTR OL BO X ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4213000102 CONTROL BO X 1 2 0601809667 CURRENT TRANSFORMER, 400/5A 3 3 0027106016 MACHINE SCREW 6 4 0601870422 CIRCUIT BREAKER, 600A 1 4 A 0021006045 MACHINE SCREW ................[...]

  • Page 80

    P A GE 80 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — CONTR OL BO X ASSY . (CONT)[...]

  • Page 81

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 81 1 DCA220SSJ/SSJU — CONTR OL BO X ASSY . (CONT) NO . P AR T NO . P AR T NAME QTY . REMARKS 3 0 L Y2DUS12VDC RELA Y .......................................................... 1 ................ REPLACES P/N 0601827656 30 A PTF08A BASE .................................[...]

  • Page 82

    P A GE 82 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU— ENGINE AND RADIA T OR ASSY .[...]

  • Page 83

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 83 1 DCA220SSJ/SSJU — ENGINE AND RADIA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4923200034 ENGINE, JOHN DEERE 6068HF485 1 1- 1 0602041292 OIL FIL TER CAR TRIDGE, OIL FIL TER ........... 1 ......... RE504836 1- 2 0602042596 PRIMAR Y FUEL FIL TER CARTRID[...]

  • Page 84

    P A GE 84 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENGINE AND RADIA T OR ASSY .[...]

  • Page 85

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 85 1 DCA220SSJ/SSJU — ENGINE AND RADIA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 3 2 M4310301203 F A N S H ROU D 1 32A M4493601204 ACOUSTIC SHEET ......................................... 1 ........... DCA220SSJ 33 0016908020 HEX HEAD BOL T 6 34 0016908020[...]

  • Page 86

    P A GE 86 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENGINE AND RADIA T OR ASSY .[...]

  • Page 87

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 87 1 NO . P AR T NO . P AR T NAME QTY . REMARKS 70 0602021070 CA P 1 71 0269200660 DRAIN HOSE 1 72 0802081003 RESER VE T ANK .............................................. 1 .......... DCA220SSJ 7 2 M9300000203 RESER VE T ANK .............................................[...]

  • Page 88

    P A GE 88 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — OUTPUT TERMINAL ASSY .[...]

  • Page 89

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 89 1 DCA220SSJ/SSJU — OUTPUT TERMINAL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4230700003 TERMINAL BOARD ..................................................... 1 ........... DCA220SSJ 1 M4230700113 TERMINAL BOARD .............................................[...]

  • Page 90

    P A GE 90 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — OUTPUT TERMINAL ASSY . (CONT .)[...]

  • Page 91

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 91 1 NO . P AR T NO . P AR T NAME QTY . REMARKS 21 0601850275 GROMMET 1 22 0601851780 GROMMET .................................................................. 2 ........... DCA220SSJ 22 0603306775 GROMMET ................................................................[...]

  • Page 92

    P A GE 92 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — B A TTER Y ASSY .[...]

  • Page 93

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 93 1 DCA220SSJ/SSJU — B A TTER Y ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0168614551 BA TTER Y .................................................................. 1 .............. DCA220SSJ 2 C9109100604 B A T T ERY SHEET .....................................[...]

  • Page 94

    P A GE 94 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — MUFFLER ASSY .[...]

  • Page 95

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 95 1 DCA220SSJ/SSJU — MUFFLER ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4330100602 MUFFLER 1 2 0016910025 HEX. HEAD BOL T 4 3 M4333000303 EXHA UST PIPE 1 4 0602325066 CLAMP 1 5 M4333200004 GASKET 1 6 0010112055 HEX. HEAD BOL T ...............................[...]

  • Page 96

    P A GE 96 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — FUEL T ANK ASSY .[...]

  • Page 97

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 97 1 NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C1363001403 FUEL T ANK .................................................................. 1 ........... DCA220SSJ 1- 1 0845500104 C A P , FUEL T ANK ......................................................... 1 ........... [...]

  • Page 98

    P A GE 98 — DCA-220SSJ/SSJU — OPERA TION AND P AR TS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENCLOSURE ASSY .[...]

  • Page 99

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 99 1 DCA220SSJ/SSJU — ENCLOSURE ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C1413004402 BASE ........................................................................... 1 ........... DCA220SSJ 1 M4413000302 BASE .................................................[...]

  • Page 100

    P A GE 100 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENCLOSURE ASSY . (CONT .)[...]

  • Page 101

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 101 1 DCA220SSJ/SSJU — ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 18 A 0030014000 H E X N U T 4 18 B 0040014000 W A SHER, LOCK 4 18 C 0041214000 W ASHER, FLA T 8 19 0010120045 HEX HEAD BOL T ....................................................[...]

  • Page 102

    P A GE 102 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENCLOSURE ASSY . (CONT .)[...]

  • Page 103

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 103 1 DCA220SSJ/SSJU — ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 3 9 M4463200202 R OOF P ANEL 1 39A M4493501903 ACOUSTIC SHEET 1 4 0 M4463200403 REAR ROOF DUCT 1 40A M4493502004 ACOUSTIC SHEET 1 41 0016908020 HEX HEAD BOL T 1 0 4 2 M446340000[...]

  • Page 104

    P A GE 104 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — ENCLOSURE ASSY . (CONT .)[...]

  • Page 105

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 105 1 NO . P AR T NO . P AR T NAME QTY . REMARKS 6 1 M9113000102 DOOR HANDLE 3 62 0021806016 MACHINE SCREW 2 8 62 A 0030006000 HEX. NUT 2 8 6 3 M4453600004 GUTTER 3 6 4 M4453600104 GUTTER 2 65 0019206016 HEX. HEAD BOL T 1 5 66 0845046904 HINGE 6 66 A 0845045004 W ASHER .[...]

  • Page 106

    P A GE 106 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — R UBBER SEALS ASSY .[...]

  • Page 107

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 107 1 DCA220SSJ/SSJU — R UBBER SEALS ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0229201240 SEAL, R UBBER 4 2 0228900945 SEAL, R UBBER 4 3 0228901200 SEAL, R UBBER 3 4 0228901260 SEAL, R UBBER 3 5 0228901055 SEAL, R UBBER 4 6 0228900600 SEAL, R UBBER 1 7 022890[...]

  • Page 108

    P A GE 108 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — NAMEPLA TE AND DECALS ASSY .[...]

  • Page 109

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 109 1 DCA220SSJ/SSJU — NAMEPLA TE AND DECALS ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1- 1 M4550000303 DE C A L ; OPERA TING PR OCEDURES ........................ 1 ........... M45000030 1- 2 B9521100404 DE C A L ; SAFETY INSTR UCTIONS .........................[...]

  • Page 110

    P A GE 110 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) DCA220SSJ/SSJU — NAMEPLA TE AND DECALS ASSY . (CONT .)[...]

  • Page 111

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 111 1 NO . P AR T NO . P AR T NAME QTY . REMARKS B A TTER Y GROUP 5- 1 0800689504 DECAL; - ...................................................................... 1 ........... S2091, DCA220SSJ 5- 1 M9500300004 DECAL; - ....................................................[...]

  • Page 112

    P A GE 112 — DCA-220SSJ/SSJU — OPERA TION AND P ARTS MANU AL — REV . #1 (02/28/14) TERMS AND CONDITIONS OF SALE — P A R TS P A YMENT TER MS T erms of payment for part s are net 30 days. FREIGHT P OLICY All parts orders will be shipped collect or prepaid with the c harges ad ded to the invoice. All shipments are F .O.B. point of origin. Mult[...]

  • Page 113

    DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #1 (02/28/14) — PAGE 113 1 NO TE P A GE[...]

  • Page 114

    P AR TS AND OPERA TION MANUAL OPERA TION AND P AR TS MANUAL Y our Local Dealer is: HERE’S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2014, MUL TIQUIP INC . Multiquip Inc , the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permissi on.[...]