Multiquip DCA-220SSJ manual

P AR TS AND OPERA TION MANUAL OPERA TION AND P AR TS MANUAL Re vision #1 (01/06/09) THIS MANU AL MUST A CCOMP ANY THE EQUIPMENT A T ALL TIMES. WHISPER W A TT TM SERIES MODELS DCA-220SSJ DCA-220SSJU 50 Hz GENERA TOR P ARTS LIST NO . C1870300404[...]

P A GE 2 — DCA-220SSJ/SSJU— OPERA TION AND P A RTS MANU AL — REV . #1 (01/06/09) Diesel engine exhaust and some of PR OPOSITION 65 W ARNING[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 3 1 NO TES[...]

P A GE 4 — DCA-220SSJ/SSJU— OPERA TION AND P A RTS MANU AL — REV . #1 (01/06/09) T ABLE OF CONTENTS Specification and part number are subject to change without notice . NO TE 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 [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 5 1 P ARTS ORDERING PR OCEDURES www .mqpo wer.com Best Deal! Ordering parts has never been easier! Choose from three easy options: WE ACCEPT ALL MAJOR CREDIT CARDS! When ordering parts, please supply: ❒ ❒ ❒ ❒ ❒ Dealer Account Number ❒ ❒ ❒ ❒ ❒ Dealer Na[...]

P A GE 6 — DCA-220SSJ/SSJU— OPERA TION AND P A RTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — SPECIFICA TIONS Generator Specifications T ab le 1. Model DCA-220SSJ/SSJU T ype Re v olving field, self ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase 3 Standby Output 193 KV A (154 KW) Prim[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 [...]

P A GE 8 — DCA-220SSJ/SSJU— OPERA TION AND P A RTS MANU AL — REV . #1 (01/06/09) This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ P o wer Model DCA-220SSJ/ SSJU Whisperwatt™ Generator . Bef ore using this g enerator , ensure that the operating individual has read and[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 9 1 DCA-220SSJ/SSJU — SAFETY MESSA GE ALER T 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[...]

P A GE 10 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 ser vice this equipment before reading this entire manual[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 11 1 DCA-220SSJ/SSJU — R ULES FOR SAFE OPERA TION POWER CORD (POWER ON) WET HANDS Dur ing 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 av oid these hazard[...]

P A GE 12 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 i[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 know the location of the nearest phone or keep a phone on the job site, in case of emergencies. ■ AL W A[...]

P A GE 14 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 information. The illustration belo w and on the preceding page show the decals as they appear on the mac[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 15 1 DCA-220SSJ/SSJU — GENERA T OR DECALS Figure 3. Generator Decals (Cont inued)[...]

P A GE 16 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) Figure 4. T ypical Generator Grounding Application DCA-220SSJ/SSJU — INST ALLA TION[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 w[...]

P A GE 18 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — GENERAL INFORMA TION DCA-220SSJ/SSJU Whisperwatt™ Series Familiarization Generator The MQ P ow er Model DCA-220SSJ/SSJU is a 140 kW generator (Figure 5) that is designed as a high quality por tab le (requires a trailer f or transpor t) pow e[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 19 1 DCA-220SSJ/SSJU — MAJOR COMPONENTS Figure 5. Major Components Denyo 9 11 220 AUTO MANUAL OFF/RESET LOWOIL PRESSURE HIGHCOOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINERUNNING MOOOOO-20001Q 1 2 3 4 5 6 7 8 10 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 [...]

P A GE 20 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 Con[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 21 1 First Time Star t 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 f or engines with a pre-star tup sequence . Once the “W ait to Star t” message is no longer di[...]

P A GE 22 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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” b utton to retur n to the main menu displa y . Stor[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 23 1 First Time Star t 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 f or engines with a pre-star tup sequence . Once the “W ait to Star t” message is no longer di[...]

P A GE 24 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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” b utton to retur n to the main menu displa y . Stor[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 Button[...]

P A GE 26 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) ! ! ! Indicates Auxiliary Gage Fault Indicates Fault Warning Indicates Derate or Shutdown Condition Fault 5. T ouching the “Enter Button” will redisplay the hidden f ault. T ouching the “Enter Button” once again will hide the fault and return the screen t[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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” me[...]

P A GE 28 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 n [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 29 1 Select Units 1. Star ting at 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 arrow buttons to scroll through the menu until the “Select Units” is highlighted. 3. Once the “Select [...]

P A GE 30 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 o[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 31 1 1 1 . T ouch the “Enter Button” to deselect the selected parameter removing it from the list of parameters being displa y ed 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[...]

P A GE 32 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 “[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 paramet[...]

P A GE 34 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 But[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 35 1 1 1 . T ouch the “Menu” b utton to retur n to “Utilities” menu. T ouch the “Men u b utton again to retur n to the “Main” menu. MODBUS SETUP 1 . Star ting at the single or f our engine parameter displa y , touch the “Menu Button”. 2 . The main menu w[...]

P A GE 36 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 displa y ed f or at least 5 seconds. NO T SUPP[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 50 Hz. 2. A C Ammeter ?[...]

P A GE 38 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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. When[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 39 1 DCA-220SSJ/SSJU — ENGINE OPERA TING P ANEL 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 (f or star ting during cold weather operating conditiions). Whe[...]

P A GE 40 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) Output T erminal F amiliarization The “ Output T erminal P anel ” (Figure 8) is provided with the following: ■ ■ ■ ■ ■ Three (3) 100/200V output receptacles @ 50 amp ■ ■ ■ ■ ■ Three (3) Circuit Breakers @ 50 amps ■ ■ ■ ■ ■ T wo ([...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 41 1 100 V A C GFCI Receptac les There are two 100 V A C , 20 amp GFCI (Duple x Nema 5-20R) recepacles pro vided on the output ter minal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit brea[...]

P A GE 42 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 protec[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 w attage, amperage , frequency , and voltage requirements are satisfactorily supplied by the generator for operating the equipm[...]

P A GE 44 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — GENERA T OR OUTPUTS Generator Amperage T ables 8 and 9 describe 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 voltage f[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 45 1 Maximum Amps T able 10 sho ws 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 Gaug e . The AC ammeter and AC voltmeter change-over switches on the control panel DO NO T eff ect the generator [...]

P A GE 46 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) Figure 21. V oltage Change-Over Board 200V Configuration UVWO T erminal Output V oltages V ar ious 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 t[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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-400V UVW O T erminal Output V oltages 1 . Jumper the voltage change-over board for 480V operation as shown in Figure 26. This configurati[...]

P A GE 48 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — PRE-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 [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 49 1 DCA-220SSJ/SSJU — PRE-SETUP Refueling Procedure: 1. Le vel T anks – Make sure fuel cells are le v el 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 ONL Y! u[...]

P A GE 50 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 able 12 f or engine , radiator , and reco very tank coolant capacities. Make sure the[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 51 1 DCA-220SSJ/SSJU — PRE-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 TO position. AL W A YS make sure that the MPEC Control Switch is in the OF[...]

P A GE 52 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) Starting (Manual) 1. Place the engine speed switch (Figure 41) in the “ LO W ” (down) position Figure 42. MPEC Control Switch (Manual P osition) DCA-220SSJ/SSJU — GENERA T OR ST AR T -UP PR OCEDURE (MANU AL) The engine's exhaust contains harmful emissi[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 an y abnor malities exists , the W ar ning and Emergency Stop lamps on the Engine Operating P anel will be lit. 4. Place the MPEC Contr[...]

P A GE 54 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) When the generator is set in the AU TO mode, the generator will automically start in the event of comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch. NO TE Starting (Auto Mode) Befor[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 55 1 1. P erf or m steps 1 through 6 in the Bef ore Star ting 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 [...]

P A GE 56 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) Normal Shutdown Procedure T o shutdown the generator 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 switch (Figure 56) in the “ LO W ” (down) positio[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 power , e xcessiv e carbon buildup in the comb ustion chamber and high fuel consump[...]

P A GE 58 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 and [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 59 1 DCA-220SSJ/SSJU — MAINTENANCE (HEA TER/CHARGER) T o ensure adequate star ting capability , alwa ys hav e power applied to the generator's internal battery charger . NOTE If the generator will be used daily , the batter y should nor mally not require charging. [...]

P A GE 60 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 y [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — 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 for[...]

P A GE 62 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) 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 press[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 63 1 NEVER use an pneumatic air gun to tighten wheel lug nuts. Figure 62. Wheel Lug Nuts Tightening Sequence DCA-220SSJ/SSJU — MAINTENANCE (TRAILER) NOTE Lug Nut T orque Requirements It is e xtremely impor tant to apply and maintain proper wheel mounting torque on the t[...]

P A GE 64 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — TRAILER WIRING DIA GRAM Figure 63. T railer/T owing V ehic le Wiring Diagram[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 65 1 DCA-220SSJ/SSJU — GENERA T OR WIRING DIA GRAM Figure 64. Generator Wiring Diagram[...]

P A GE 66 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — ENGINE WIRING DIA GRAM Figure 65. Engine Wiring Diagram[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 67 1 Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdo wn, use T ab le 19 shown belo w f or diagnosis of the Generator . If the problem cannot be remedied, consult our company's business office o[...]

P A GE 68 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — TROUBLESHOO 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 ab le 20 (Engine Controller T roubleshooting) as a basic guideline f or tr[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 69 1 NO TE P A GE[...]

P A GE 70 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — EXPLANA TION OF CODE IN REMARKS COLUMN NO TE When ordering a part that has more than one item number listed, check the remarks column for help in deter mining the proper par t to order . QTY . Column Numbers Used - Item quantity can be indicat[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 71 1 DCA-220SSJ/SSJU — SUGGESTED SP ARE P AR TS P ar t number on this Suggested Spare P ar ts list may supercede/replace the P/N shown in the text pages of this book. NOTE DCA-220SSJ/SSJU WHISPER W A TTGENRA T OR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 T O 3 UNITS [...]

P A GE 72 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU — GENERA T OR ASSY . GENERA T OR ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 73 1 DCA-220SSJ/SSJU — GENERA T OR ASSY . GENERA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C1110000002 ROT O R ASSEMBL Y .................................. 1 ............. INCLUDES ITEMS W/ * 1-1 * FIELD ASSEMBL Y 1 1-2 * 0601842334 R E S I S T OR, 80W 10[...]

P A GE 74 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) GENERA T OR ASSY . DCA-220SSJ/SSJU — GENERA T OR ASSY . (CONT .)[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 75 1 GENERA T OR ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 10 0012110065 HEX. HEAD BOL T 4 10 A 0042610000 SPRING W ASHER 4 10 B 0041210000 PLAIN W ASHER 4 11 0017112045 HEX. HEAD BOL T 6 12 C1154400004 CO VER, BEARING 1 13 C1154300004 GASKET , BEARING 1 [...]

P A GE 76 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— CONTR OL P ANEL ASSY . CONTR OL P ANEL ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 77 1 DCA-220SSJ/SSJU— CONTR OL P ANEL ASSY . CONTR OL P ANEL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4223000303 CONTR OL P ANEL 1 2 M4223000404 CONTR OL 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[...]

P A GE 78 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— CONTR OL BO X ASSY . CONTR OL BO X ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 79 1 DCA-220SSJ/SSJU— CONTR OL BO X ASSY . CONTR OL BO X ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4213000102 CONTR OL BO X 1 2 0601809667 CURRENT TRANSFORMER, 400/5A 3 3 0027106016 MACHINE SCREW 6 4 0601870422 CIRCUIT BREAKER, 600A 1 5 0601815168 REAR CONNEC[...]

P A GE 80 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) CONTR OL BO X ASSY . (CONT .) DCA-220SSJ/SSJU— CONTR OL BO X ASSY . (CONT)[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 81 1 DCA-220SSJ/SSJU— CONTR OL BO X ASSY . (CONT) CONTR OL BO X ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 38 0027106020 MACHINE SCREW 1 39 0601802218 FUSE HOLDER, 3P 1 39 A 0601806653 FUSE (RIGHT SIDE) 20A 1 39 B 0601802149 FUSE ( CENTER) 10A 1 40 0027103020 MAC[...]

P A GE 82 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 83 1 DCA-220SSJ/SSJU— ENGINE AND RADIA T OR ASSY . 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 CARTRIDGE, OIL FIL TER ........... 1 ......... RE504836 1- 2 0602042596 PR[...]

P A GE 84 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 85 1 DCA-220SSJ/SSJU— ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 3 2 M4310301203 F AN S H RO U D 1 M4493601204 ACOUSTIC SHEET 1 33 0016908020 HEX HEAD BOL T 6 34 0016908020 HEX HEAD BOL T 4 3 5 M4310300903 F A N [...]

P A GE 86 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 87 1 ENGINE AND RADIA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 70 0602021070 C A P 1 71 0269200660 DRAIN HOSE 1 72 0802081003 RESER VE T ANK 1 73 0602010900 RESER VE T ANK CAP 1 7 4 M4316100103 RESER VE T ANK BRA CKET 1 75 0016910025 HEX HEAD BOL T 2 76 0199[...]

P A GE 88 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 89 1 DCA-220SSJ/SSJU— OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4230700003 TERMINAL BOARD 1 2 M9220100304 OUTPUT TERMINAL BOL T 8 3 0801830804 TIE BOL T 8 4 0039316000 HEX. NUT 1 6 5 0040016000 SPRING W ASHER 2 4 6 00414[...]

P A GE 90 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— B A TTER Y ASSY . BA TTER Y ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 91 1 DCA-220SSJ/SSJU— B A TTER Y ASSY . BA TTER Y ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0168614551 B A TT E R Y , 145G51 1 2 C9109100604 B A T T E R Y SHEET 1 3 0805000904 B A T T E R Y BAND 1 4 0805002904 B A T T E R Y B O L T 2 5 0037808000 WING NUT 2 6 [...]

P A GE 92 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— MUFFLER ASSY . MUFFLER ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 93 1 DCA-220SSJ/SSJU— MUFFLER ASSY . 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 4 6 A 0040012000 [...]

P A GE 94 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— FUEL T ANK ASSY . FUEL T ANK ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 95 1 DCA-220SSJ/SSJU— FUEL T ANK ASSY . FUEL T ANK ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C1363001403 FUEL T ANK 1 1- 1 0845500104 C A P , FUEL T ANK 1 1- 2 0810105400 FUEL FIL TER 1 2 0605501092 FUEL GA UGE SENDER 1 2 A 0605516090 GASKET 1 3 0022905015 MAC[...]

P A GE 96 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENCLOSURE ASSY . ENCLOSURE ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLOWING DIGITS AFTER THE P AR T NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CA TERPILLAR YELLOW 3-SPECTRUM GRE[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 97 1 DCA-220SSJ/SSJU— ENCLOSURE ASSY . ENCLOSURE ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C1413004402 BASE 1 2 M1413400404 CO VER 1 3 0019208020 HEX. HEAD BOL T 4 4 M4423000302 FRONT FRAME 1 4A M4493102503 ACOUSTIC SHEET 1 5 M4423000402 FRONT FRAME 1 5A M4493[...]

P A GE 98 — DCA-220SSJ/SSJU— OPERA TION AND P ARTS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT .) THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLOWING DIGITS AFTER THE P AR T NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CA TERPILLAR YEL[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 99 1 DCA-220SSJ/SSJU— ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 24 0207306000 HEX. NUT 1 1 25 0019208020 HEX. HEAD BOL T 1 0 2 6 M4443200403 DOOR, REAR FRAME 1 2 7 M4443600004 WINDO W PLA TE 1 28 0207306000 HEX. NUT 8[...]

P A GE 100 — DCA-220SSJ/SSJU— OPERA TION AND P A R TS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT .) THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLOWING DIGITS AFTER THE P AR T NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CA TERPILLAR [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 101 1 DCA-220SSJ/SSJU— ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 5 1 M4453001203 SIDE DOOR 1 51A M4493403804 ACOUSTIC SHEET 1 5 2 M4453001303 SIDE DOOR 1 52A M4493403904 ACOUSTIC SHEET 1 5 3 M4453001003 SIDE DOOR 1 53[...]

P A GE 102 — DCA-220SSJ/SSJU— OPERA TION AND P A R TS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— R UBBER SEALS ASSY . R UBBER SEALS ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 103 1 DCA-220SSJ/SSJU— R UBBER SEALS ASSY . 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 UB[...]

P A GE 104 — DCA-220SSJ/SSJU— OPERA TION AND P A R TS MANU AL — REV . #1 (01/06/09) DCA-220SSJ/SSJU— NAMEPLA TE AND DECALS ASSY . NAMEPLA TE AND DECALS ASSY .[...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 105 1 DCA-220SSJ/SSJU— NAMEPLA TE AND DECALS ASSY . 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 UCTIO[...]

P A GE 106 — DCA-220SSJ/SSJU— OPERA TION AND P A R TS MANU AL — REV . #1 (01/06/09) Effective: February 22, 2006 TERMS AND CONDITIONS OF SALE — P AR TS P A YMENT TERMS T er ms of pa yment f or par ts are net 30 da ys. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are [...]

DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 107 1 NO TE P A GE[...]

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