Multiquip Mq Power Whisperwatt 50 Hz Generator Dca 220Ssj Users Manual DCA220SSJ SSJU Rev 1.PMD
MQ Power Whisperwatt 50 Hz Generator DCA-220SSJ Generators_portable_whisperwatt_DCA220SSJ_SSJU_rev_1_50_hz_manual_DataId_19096_Version_1
DCA-220SSJ to the manual 9b9035dd-b5b0-4fdc-ae28-f66bb6b2f332
2015-02-09
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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
Revision #1 (01/06/09)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
WHISPERWATTTM SERIES
MODELS
DCA-220SSJ
DCA-220SSJU
50 Hz GENERATOR
PARTS LIST NO. C1870300404
PAGE 2 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Diesel engine exhaust and some of
PROPOSITION 65 WARNING
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 3
1
NOTES
PAGE 4 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
TABLE OF CONTENTS
Specification and part
number are subject to
change without notice.
NOTE
MQ POWER DCA-220SSJ/SSJUMQ POWER DCA-220SSJ/SSJU
MQ POWER DCA-220SSJ/SSJUMQ POWER DCA-220SSJ/SSJU
MQ POWER DCA-220SSJ/SSJU
WHISPERWHISPER
WHISPERWHISPER
WHISPERWW
WW
WAA
AA
ATTTT
TTTT
TTTMTM
TMTM
TM
GENERATORGENERATOR
GENERATORGENERATOR
GENERATOR
Proposition 65 Warning ..................................................... 2
Table Of Contents ............................................................. 4
Parts Ordering Procedures ............................................... 5
Specifications ................................................................... 6
Dimensions (Top, Side, Front) ........................................... 7
Safety Message Alert Symbols .................................... 8-9
Rules for Safe Operation ........................................... 10-13
Generator Decals ....................................................... 14-15
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Diagnostic Display ..................................................... 20-36
Generator Control Panel ................................................. 37
Engine Operating Panel ............................................. 38-39
Output Terminal Panel Familiarization ........................ 40-42
Load Application ............................................................. 43
Generator Outputs .......................................................... 44
Gauge Reading ............................................................... 45
Output Terminal Panel Connections ................................ 46
Setup .............................................................................. 47
Generator Start-up Procedure (Manual) ..................... 52-54
Generator Start-up Procedure (Auto Mode) .................... 55
Generator Shut-Down Procedure .................................... 56
Maintenance (Engine) ................................................ 57-58
Maintenance Jacket Water Heater/Battery Charger ........ 59
Maintenance (Trailer) ................................................. 60-63
Trailer Wiring Diagram ..................................................... 64
Generator Wiring Diagram ............................................... 65
Engine Wiring Diagram ................................................... 66
Generator Troubleshooting .............................................. 67
Engine Controller Troubleshooting ................................... 68
Explanation of Code in Remarks Column ....................... 70
Suggested Spare Parts .................................................. 71
Generator Assembly .................................................. 72-74
Control Panel Assembly ............................................ 76-77
Control Box Assembly ............................................... 78-81
Engine and Radiator Assembly ................................. 82-87
Output Terminal Assembly ......................................... 88-89
Battery Assembly ...................................................... 90-91
Muffler Assembly ...................................................... 92-93
Fuel Tank Assembly .................................................. 94-95
Enclosure Assembly ............................................... 96-101
Rubber Seals Assembly ........................................ 102-103
Nameplate and Decals .......................................... 104-105
Terms and Condition of Sale — Parts .......................... 106
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 5
1
PARTS ORDERING PROCEDURES
www.mqpower.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 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/Fed Ex
✓ DHL
■
Priority One
✓
Tr u ck
■
Ground
■Next Day
■
Second/Third Day
All orders are treated as
Standard Orders
and will ship the same day if received prior
to 3PM PST.
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact you
r
District Sales Manager for more information.
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
■
Print Specification Information
Note: Discounts Are Subject To Change
Goto www.multiquip.com and click on
Order Parts to log in and save!
Use the
internet
and qualify for a 5% Discount
on
Standard orders
for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Fax
your order in and qualify for a 2% Discount
on
Standard orders
for all orders which include
complete part numbers.*
Order via Phone: Domestic (US) Dealers Call:
1-800-427-1244
International Customers
should contact
their local Multiquip Representatives for
Parts Ordering information.
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
Note: Discounts Are Subject To Change
Effective:
January 1st, 2006
PAGE 6 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — SPECIFICATIONS
Generator SpecificationsTable 1.
Model DCA-220SSJ/SSJU
Type Revolving field, self ventilated, open protected type
synchronous generator
Armature Connection Star with Neutral
Phase 3
Standby Output 193 KVA (154 KW)
Prime Output 176 KVA (140 KW)
Voltage 200, OR 400V
Frequency 50 Hz
Speed 1500 rpm
Power Factor 0.8
AUX. AC Power Single Phase, 50 Hz
Voltage 100V
Output 4.8 KW (2.4 KW X 2)
Dry Weight 6,895 lbs. (3,130 kg.)
Wet Weight 7,753 lbs. (3,520 kg.)
Engine SpecificationsTable 2.
Model JOHN DEERE 6068HF485
Type 4 cycle, water-cooled, direct injection, turbo-charged with
charged air-cooled
No. of Cylinders 6 cylinders
Bore x Stroke 4.17 in. x 5.00 in. (106 mm x 127 mm)
Displacement 415 cu. in. (6.8 liters)
Starting Electric 12VDC
Cooling Capacity 6.4 gal. (24 liters)
Lube Oil Capacity 8.19 gal. (31 liters)
Fuel Type #2 Diesel Fuel
Fuel Tank Capacity 100 gal. (380 liters)
Battery 128Ah x 1
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 7
1
DCA-220SSJ/SSJU — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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retteL ).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD
A).mm049(.ni00.73F ).mm005,3(.ni08.731
B).mm0
49(.ni00.73G ).mm007,1(.ni29.66
C).mm050,1(.ni33.14H ).mm042,1(.ni18.84
D).mm050,1(.ni33.14
E).mm050,1(.ni33.14
PAGE 8 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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 Power
Model DCA-220SSJ/
SSJU Whisperwatt™ Generator.
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.
FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
Hazard Symbols
" which
appear throughout this manual, and will be referenced in
conjunction with Safety "
Message Alert Symbols
".
NOTE
DCA-220SSJ/SSJU — SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
You CAN be injured if you do not follow directions
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH
if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
Gasoline
is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
Engine components can generate extreme
heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
WARNING
DANGER
CAUTION
WARNING - LETHAL EXHAUST GASES
WARNING - BURN HAZARDS
WARNING - EXPLOSIVE FUEL
During operation of this generator, there
exists the possibility of
electrocution,
electrical shock or burn,
which can cause
severe bodily harm
or even
DEATH!
DANGER - ELECTROCUTION HAZARDS
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 9
1
DCA-220SSJ/SSJU — SAFETY MESSAGE ALERT SYMBOLS
ALWAYS place the MPEC control switch
in the OFF/RESET position when the
generator is not in use.
ALWAYS wear approved
respiratory
protection.
ALWAYS wear approved
eye
and
hearing
protection.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property, or
the surrounding environment
could be damaged if you do not
follow instructions.
NOTE
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - ACCIDENTAL STARTING
CAUTION - RESPIRATORY HAZARDS
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER operate equipment with covers,
or guards removed. Keep
fingers
,
hands
,
hair
and clothing away from all moving
parts to prevent injury.
WARNING - ROTATING PARTS
PAGE 10 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION
The following safety guidelines should always be used when
operating the
DCA-220SSJ/SSJU Whisperwatt™ AC
Generator.
General Safety:
■
DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
This equipment should not be operated by persons under
18 years of age.
■
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the influence or
drugs or alcohol.
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.
DANGER - READ THIS MANUAL!
■
ALWAYS check the machine for loosened threads or bolts
before starting.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe
bodily harm or even death.
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■
High Temperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot!
components can cause serious
burns.
■
The engine of this generator requires an adequate free
flow of cooling air.
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.
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
NEVER run engine without air filter. Severe engine damage
may occur.
■
DO NOT leave the generator running in the
manual mode
unattended.
■
Refer to the
John Deere Engine Owner's Manual
for
engine technical questions or information.
■
ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
■
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 11
1
DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION
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 bodily harm
or even
DEATH!
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
terminals, insufficient tightening of the terminal connections
may cause damage to the generator
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
Backfeed to a utility system can
cause
electrocution
and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation
DANGER - ELECTROCUTION HAZARDS
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the
National Electrical Code
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
The following safety recommendations should also be
followed:
■
ALWAYS make sure generator is properly grounded.
■
NEVER use gas piping as an electrical ground.
■
ALWAYS make sure that electrical circuits are properly
grounded
per the
National Electrical Code
(NEC) and
local codes before operating generator. Severe
injury
or
DEATH!
by electrocution can result from operating an
ungrounded generator.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
Electrical Safety
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the
National Electrical Code
(NEC) and local codes
before operating generator.
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 6.
■
NEVER power cables or cords
lay in wate
r.
■
NEVER
stand in water
while AC power from the generator
is being transfer to a load.
PAGE 12 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION
Battery Safety
Use the following guidelines when handling the battery:
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation,
always
wear safety
glasses.
■
Use well insulated gloves when picking up the battery.
Maintenance Safety
■
The electrical voltage required to operate the generator
can cause severe injury or even death through physical
contact with live circuits.
Turn all circuit breakers OFF
before performing maintenance on the generator.
■
NEVER lubricate components or attempt service on a
running machine.
■
ALWAYS disconnect the
NEGATIVE battery terminal
before performing service on the generator.
■
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
■
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
Keep the machinery in proper running condition.
■
Fix damage to the machine immediately and always
replace broken parts.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
■
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
WARNING - BURN HAZARDS
■■
■■
■
ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
■■
■■
■
ALWAYS keep battery charging and cables in good working
condition. Repair or replace all worn cables.
■■
■■
■
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■■
■■
■
In case the battery liquid (dilute sulfuric acid) comes in
contact with
clothing or skin
, rinse skin or clothing
immediately with plenty of water.
■■
■■
■
In case the battery liquid (dilute sulfuric acid) comes in
contact with your
EYES
, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
The risk of an explosion exists when performing service
on the battery. To avoid
severe injury
or
DEATH:
■■
■■
■
DO NOT drop the battery. There
is the possibility of risk that the
battery may explode.
■■
■■
■
DO NOT expose 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.
DANGER - EXPLOSION HAZARDS
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 13
1
Emergencies
■
ALWAYS know the location of the
nearest
fire extinguisher
.
■
ALWAYS know the location of the
nearest and
first aid kit
.
■
ALWAYS know the location of the
nearest phone or
keep a phone on
the job site,
in case of emergencies.
■
ALWAYS have easy access to the phone
numbers of the nearest
Ambulance
,
Doctor
and
Fire Department
. This information will
be invaluable in the case of an emergency.
DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION
Check with your local county or state safety towing
regulations, in addition to meeting
Department of
Transportation
(DOT)
Safety Towing Regulations
, before
towing your generator.
CAUTION - FOLLOW TOWING REGULATIONS
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
chock blocks
underneath wheel to prevent rolling,
while parked.
■
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
■
Avoid sharp turns.
■
Trailer should be adjusted to a level position at all times
when towing.
■
Raise and lock trailer wheel stand in up position when
transporting.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
support blocks
underneath the trailer’s bumper to
prevent tipping, while parked.
■
Avoid sharp turns to prevent rolling.
■
DO NOT transport generator with fuel in tank.
Towing & Transporting Safety
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
The following list of safety precautions should be followed
when towing your generator:
■
ALWAYS shutdown engine before transporting.
■
Tighten both fuel tank caps securely.
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed
Towing & Transporting Safety
guidelines for basic towing techniques.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating.”
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
■
Check the tire air pressure on both towing vehicle and
trailer.
Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
-
Connect and test electric brake operation.
-
Secure portable power cables in cable tray with tie
wraps.
PAGE 14 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
The DCA-220SSJ/SSJU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided
for operator safety and maintenance information. The illustration below and on the preceding page show the decals as
they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your
dealer.
DCA-220SSJ/SSJU — GENERATOR DECALS
Figure 2. Generator Decals
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 15
1
DCA-220SSJ/SSJU — GENERATOR DECALS
Figure 3. Generator Decals (Cont inued)
PAGE 16 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Figure 4. Typical Generator Grounding Application
DCA-220SSJ/SSJU — INSTALLATION
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 will not be discharged in the direction of nearby
homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
2. When grounding the generator (Figure 4) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
When connecting the generator
to any buildings electrical
system ALWAYS consult with
a licensed electrician.
DCA-220SSJ/SSJU — INSTALLATION
NOTE
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
CAUTION - EXHAUST HAZARD
PAGE 18 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — GENERAL INFORMATION
DCA-220SSJ/SSJU Whisperwatt™ Series Familiarization
Generator
The MQ Power Model DCA-220SSJ/SSJU is a 140 kW
generator
(Figure 5) that is designed as a high quality
portable (requires a trailer for transport) power source for
telecom sites, lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
■■
■■
■
Tachometer
■■
■■
■
Water Temperature Gauge
■■
■■
■
Oil Pressure Gauge
■■
■■
■
Charging Ammeter Gauge
■■
■■
■
Fuel Level Gauge
■■
■■
■
Engine Speed Switch
■■
■■
■
Panel Light/Panel Light Switch
■■
■■
■
Auto ON/OFF Engine Controller (MPEC)
■■
■■
■
Preheat Lamp
■■
■■
■
Warning Lamp
■■
■■
■
Emergency Stop Lamp
■■
■■
■
Emergency Stop Button
Open Delta Excitation System
The DCA-220SSJ/SSJU generator is equipped with the state
of the art "
Open-Delta
" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
fixed ceiling
" and responds
according the demands of the required load.
Engine
The DCA-220SSJ/SSJU is powered by a 6 cylinder, water
cooled, direct injection, turbocharged
John Deere
6068HF485 Turbo Diesel Engine
. This engine is designed
to meet every performance requirement for the generator.
Reference Table 1 for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Electric Governor System
The electric governor system controls the RPMs of the en-
gine. When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
Extension Cables
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 6) as a guide
for selecting proper extension cable size.
Generator Control Panel
The “Generator Control Panel” is provided with the following:
■■
■■
■
Frequency Meter (Hz)
■■
■■
■
AC Ammeter (Amps)
■■
■■
■
AC Voltmeter (Volts)
■■
■■
■
Ammeter Change-Over Switch
■■
■■
■
Voltmeter Change-Over Switch
■■
■■
■
Voltage Regulator
■■
■■
■
3-Pole, 600 amp Main Circuit Breaker
■■
■■
■
“Control Box” (located behind the Gen. Control Panel)
■■
■■
■
Automatic Voltage Regulator
■■
■■
■
Diagnostic Display
■■
■■
■
Current Transformer
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer
■■
■■
■
Starter Relay
■■
■■
■
Engine Controller (Computer Controlled)
■■
■■
■
Voltage Change-over Board
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
■■
■■
■
Three 100/200V output receptacles (CS-6369), 50A
■■
■■
■
Three auxilliary circuit breakers, 50A
■■
■■
■
Two 100V output receptacles (GFCI), 20A
■■
■■
■
Two GFCI circuit breakers, 20A
■■
■■
■
Five output terminal lugs (3Ø power)
■■
■■
■
Battery Charger (Optional)
■■
■■
■
Water Heater (Optional)
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
34
5
6
78
10
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PAGE 20 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
The diagnostic display panel located inside the control box
on the generator (Figure 6) is designed to meet the needs
for instrumentation and control of electronically controlled
engine communication using the SAEJ1939 Controller Area
Network (CAN). This diagnostic display is a multifunction
tool that enables equipment operators to view many different
engine parameters and service codes.
The keypad on the diagnostic display panel is a capacitive
touch sensing system. There are no mechanical switches to
wear or stick. This keypad (display unit) will operate in
extreme hot or cold weather conditions.
Other components in the system are microprocessor-based
components for displaying critical engine data broadcast by
an electronic engine or transmission’s Engine Control Unit
(ECU): engine RPM, oil pressure, coolant temperature,
system voltage, etc., and a combination audible alarm and
relay unit for warning and shutdown annunciation.
The Engine Control Unit (ECU) used with this generator
diagnosis engine faults that arise with the the engine control
system and the engine itself. Engine faults can be determined
by viewing the Diagnostic Trouble Codes (Active Fault Codes)
which are displayed on the Diagnostic Display Panel. See
the John Deere Engine Operator’s Manual for a complete
listing of active fault codes and countermeasures.
The following definitions describe the controls and functions
of the
Diagnostic Display
Panel
(Figure 6).
1. Menu Button – Press this button to enter or exit menu
screens.
2. Left Arrow Button– Press this button to scroll through
the screen either moving the parameter selection toward
the left or upward.
Figure 6. Diagnostic Display Panel
3. Right Arrow Button – Press this button to scroll through
the screen either moving the parameter selection toward
the right or downward.
4. Enter Key Button – Press this button to select the
parameter that is highlighted on the screen.
5. Emergency Stop LED – When lit (RED) indicates a
major fault has occured. This condition will shudown
the generator.
6. Warning LED – When lit (AMBER), indicates a engine
parameter has exceeded its limits (minor fault). The
generator will still run in this condition.
7. Display Screen – Graphical backlight LCD screen. Back
lighting is controlled via menu or external dimmer
potentiometer. The display can show either a single
parameter or a quadrant display showing four parameters
simultaneously.
8. Diagnostic Switch – When placed in the ON position,
will activate the diagnostic display panel.
9. CAN Diagnostic Connector – Controller Area Network
connector. This connector outputs diagnostic error
codes. Connect a scanner or similar device into this
connector to read error codes.
Display Parameters
The following are some of the engine and transmission
parameters displayed on the diagnostic disply panel.
■■
■■
■
Engine RPM’s
■■
■■
■
Engine Hours
■■
■■
■
System Voltage
■■
■■
■
% Engine Load at current RPM
■■
■■
■
Coolant Temperature
■■
■■
■
Oil Pressure
■■
■■
■
Fuel Economy
■■
■■
■
Current Fuel Consumption
■■
■■
■
Throttle Position
■■
■■
■
Engine Manifold Air Temperature
■■
■■
■
Active Service Codes
■■
■■
■
Set Units for Display (English or Metric)
■■
■■
■
English Configuration Parameters.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 21
1
First Time Start Up
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence. Once the “Wait to
Start” message is no longer displayed the operator may
start the engine. Note: Displays only when SAE J1939
message is supported by engine manufacturer.
3.Once the engine has started the single engine parameter
is displayed.
Main Menu Navigation
1. Starting at the single or four engine parameter display,
touch “Menu”.
WAIT TO
START
PREHEAT
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
2. The first seven items of the “Main Menu” will be
displayed. Touching the “Arrow Buttons” will scroll through
the menu selection.
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
4.Touch the Arrows” to scroll to the desired menu item or
touch “Menu” to exit the Main menu and return to the
engine parameter display.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
G
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
Selecting a Language
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted touch
the “Enter” button.
GO TO 1-UP DISPLAY
G
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
LANGUAGES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 22 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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” button to return to the main menu display.
Stored Fault Codes
1. Starting at the single or the four engine parameter
display touch the “Menu button”.
2.The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until the Stored Fault
Codes is highlighted.
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button” to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters).
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
GO TO 1-UP DISPLAY
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
4. If the word “MORE” appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.
5. Touch the “Menu Button to return to the main menu.
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Engine Configuration Data
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
GO TO 1-UP DISPLAY
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 23
1
First Time Start Up
1. When power is first applied to the diagnostic display,
the “Logo” is displayed.
2. The “Wait to Start” message will be displayed for
engines with a pre-startup sequence. Once the “Wait to
Start” message is no longer displayed the operator may
start the engine. Note: Displays only when SAE J1939
message is supported by engine manufacturer.
3.Once the engine has started the single engine parameter
is displayed.
Main Menu Navigation
1. Starting at the single or four engine parameter display,
touch “Menu”.
WAIT TO
START
PREHEAT
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
2. The first seven items of the “Main Menu” will be
displayed. Touching the “Arrow Buttons” will scroll through
the menu selection.
3. Touching the right arrow button will scroll down to reveal
the last items of “Main Menu” screen highlighting the
next item down.
4.Touch the Arrows” to scroll to the desired menu item or
touch “Menu” to exit the Main menu and return to the
engine parameter display.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
G
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
Selecting a Language
1. Starting at the main menu display use the “Arrows to
scroll to the “Language” menu and once highlighted touch
the “Enter” button.
GO TO 1-UP DISPLAY
G
STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
LANGUAGES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 24 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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” button to return to the main menu display.
Stored Fault Codes
1. Starting at the single or the four engine parameter
display touch the “Menu button”.
2.The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until the Stored Fault
Codes is highlighted.
3. Once the “Stored Fault Codes” menu item has been
highlighted touch the “Enter Button” to view the “Stored
Fault Codes” (when applicable, consult engine or
transmission manufacturer for SAE J1939 supported
parameters).
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
GO TO 1-UP DISPLAY
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
4. If the word “MORE” appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next Stored
Diagnostic Code.
5. Touch the “Menu Button to return to the main menu.
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Engine Configuration Data
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
GO TO 1-UP DISPLAY
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 25
1
2. The main menu will pop up on the display. 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” to view the engine
configuration data.
4. Use the “Arrow Buttons” to scroll through the engine
configuration data.
5. Touch the “Menu Button” to return to the main menu.
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
FAULTS AND WARNINGS
Auxiliary Gage Fault
1. During normal operation the single or four parameter
screen will be displayed.
2. The PVA Series of auxiliary gages can be attached to
the PowerView. These auxiliary gages communicate with
the Modbus master PowerView via a daisy-chained RS-
485 port. If at any time during system initialization or
normal operation an auxiliary gage should fail, the single
or four parameter screen will be replaced with the “MLink
Gage Fault” message.
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display, touch the “Enter Button”.
4. The display will return to the single or four parameter
screen.
GO TO 1-UP DISPLAY
STORED CODES
ADJUST BACKLIGHT
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENGINE CONFG
GO TO 1-UP DISPLAY
STORED CODES
ADJUST BACKLIGHT
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENGINE CONFG
ENGINE SPEED PT 1
1800 RPM
MORE
ENGINE SPEED PT 1
1800 RPM
MORE
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
1ofx
HIDE
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
1ofx
HIDE
COOL
1800 RPM
01500 3000
TEMP!
ENG RPM
!
98%
14.2
!
57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
!
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 26 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
!
!
!
Indicates Auxiliary Gage Fault
Indicates Fault Warning
Indicates Derate or Shutdown Condition Fault
5. Touching the “Enter Button” will redisplay the hidden
fault. Touching the “Enter Button” once again will hide
the fault and return the screen to the single or four
parameter display. NOTE: The fault can only be cleared
by correcting the cause of the fault condition.
ENGINE OIL PRESSURE
GAGE NOT RESPONDING
1ofx
HIDE
Active Fault Codes
1. During normal operation the single or four parameter
screen will be displayed.
2. When the PowerView receives a fault code from an
engine control unit the single or four parameter screen
will be replaced with the “Active Fault Codes” message.
3.If the word “MORE” appears above the “Arrow Buttons”,
there are more active fault codes that may be viewed.
Use the “Arrow Buttons” to scroll to the next “Active
Fault Code”.
125°F
COOL TEMP
143°F
OIL TEMP 57 PSI
1000 RPM
ENG RPM
OIL PRES
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
SPN110 FMI10
HIGH COOLANT TEMP
WARNING
1ofx
MORE HIDE
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
4. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter Button”.
5. The display will return to the single or four parameter
display but the display will contain the “Active Fault”
warning icon. Touching the “Enter Button” will redisplay
the hidden fault.
6. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four parameter
display.
7. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
SPN110 FMI10
HIGH COOLANT TEMP
1ofx
MORE HIDE
COOL
1800 RPM
01500 3000
TEMP!
ENG RPM
!
98%
14.2
!
57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
!
SPN110 FMI10
HIGH COOLANT TEMP
WARNING
1ofx
MORE HIDE
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
!
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
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”
message.
3. To acknowledge and “Hide” the fault and return to the
single or four parameter display touch the “Enter Button”.
4. The display will return to the single or four parameter
display, but the display will contain the “Shut Down”
icon. Touching the “Enter Button” will redisplay the hidden
fault.
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
SPN110 FMI10
HIGH COOLANT TEMP
SHUTDOWN
1ofx
MORE HIDE
SPN110 FMI10
HIGH COOLANT TEMP
SHUTDOWN
1ofx
MORE HIDE
COOL
1800 RPM
01500 3000
TEMP!
ENG RPM
!
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
!
5. Touching the “Enter Button” once again will hide the
fault and return the screen to the single or four parameter
display.
6. The Single or Four parameter screen will display the
fault icon until the fault condition is corrected. NOTE:
Ignoring active fault codes could result in severe engine
damage.
SPN110 FMI10
HIGH COOLANT TEMP
SHUTDOWN
1ofx
MORE HIDE
COOL
1800 RPM
01500 3000
TEMP!
ENG RPM
!
98%
14.2
!
57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
!
Backlight Adjustment
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
2. The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until the “Adjust
Backlight” is highlighted.
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
GENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 28 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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. Touch the “Menu Button” to return to the main menu.
6. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Contrast Adjustment
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
2. The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until “Adjust Contrast”
is highlighted.
3. Once the “Adjust Contrast” menu item has been
highlighted touch the “Enter Button” to activate the
“Adjust Contrast” function.
4. Use the “Arrow Buttons” to select the desired contrast
intensity.
5. Touching the “Menu Button” will take you back through
the menus.
GO TO 1-UP DISPLAY
STORED CODES
GENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
ADJUST BACKLIGHT
ADJUST BACKLIGHT
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
ADJUST CONTRAST
ADJUST CONTRAST
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 29
1
Select Units
1. Starting at the single or four engine parameter display
touch the “Menu Button”.
2. The main menu will pop up on the display. Use the arrow
buttons to scroll through the menu until the “Select
Units” is highlighted.
3. Once the “Select Units” menu item has been highlighted
touch the “Enter Button” to access the “Select Units”
function.
4. Use the arrows to highlight the desired units. “English”
for imperial units i.e. PSI,”F or Metric kPa, Metric Bar
for IS units i.e. kPa, Bar, “C.
5. Touch the “Enter Button” to select the highlighted units.
6. Touch the “Menu Button” to return to the “Main Menu”.
7. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Setup 1- Up Display
1. Starting at the single engine parameter display, touch
the “Menu Button”.
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
GO TO 1-UP DISPLAY
STORED CODES
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
ENGLISH
ESPANOL
FRANCAIS
DEUTSCH
ENGLISH
METRIC KPA
METRIC BAR
ENGLISH
METRIC KPA
METRIC BAR
*
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the
“Setup 1-up Display” is highlighted.
GO TO 1-UP DISPLAY
STORED CODES
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
SETUP 1-UP DISPLAY
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 30 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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
display.
a). Use defaults- This option contains a set of engine
parameters: Engine Hours, Engine RPM. System
Voltage, Battery Voltage, % Engine Load at Current
RPM, Coolant Temperature, Oil Pressure.
b). Custom Setup- This option allows for the
modification of what parameter, the number of
parameters, and the order in which the parameters
are being displayed.
c). Automatic scan - Selecting the scan function will
cause the 1-Up Display to scroll through the
selected set of parameters one at a time,
momentarily pausing at each.
5. Use Defaults- To select “Use Defaults” use the arrow
buttons to scroll to and highlight “Use Defaults” in the
menu display.
6. Touch the “Enter Button” to activate the “Use Defaults”
function.
GO TO 1-UP DISPLAY
STORED CODES
G
ADJUST BACKLIGHT
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
SETUP 1-UP DISPLAY
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
7. A message indicating the “Single Engine” parameter
display parameters are reset to the factory defaults will
be displayed, then the display will return to the “Custom
Setup” menu.
8. Custom Setup- To perform a custom setup of the 1-Up
Display, use the arrow buttons to scroll to and highlight
“Custom Setup” on the display.
9. Touching the “Enter Button” will display a list of engine
parameters.
10. Use the “Arrow Buttons” to scroll to and highlight a
selected parameter (parameter with a # symbol to right
of it).
RESTORED TO
DEFAULTS
USE DEFAULTS
AUTOMATIC SCAN OFF
CUSTOM SETUP
USE DEFAULTS
AUTOMATIC SCAN OFF
CUSTOM SETUP
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
1
3
2
This number indicates
the order of display for the
parameters and that the
parameter is selected
for display.
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 31
1
11. Touch the “Enter Button” to deselect the selected
parameter removing it from the list of parameters being
displayed on the 1-up display.
12. Use the “Arrow Button” to scroll and highlight the desired
parameter that has not been selected for display.
13. Touch the “Enter Button” to select the highlighted
parameter for inclusion in the Single Engine Parameter
Display.
14. Continue to scroll and select additional parameters for
the custom 1-up Display. Touch the “Menu Button” at
any time to return to the “Custom Setup” menu.
15. Automatic Scan- Selecting the scan function will cause
the 1-Up Display to scroll through the selected set of
parameters one at a time. Use the “Arrow Buttons” to
scroll to the “Automatic Scan” function.
16. Touching the “Enter Button” toggles the “Automatic
Scan” function on.
17. Touching the “Enter Button” again toggles the “Automatic
Scan” function off.
18. Once the “Use Defaults”, “Custom Setup” and “Automatic
Scan” functions have been set touch the “Menu Button”
to return to the main menu.
19. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
1
3
2
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
Note that the numbers
now indicate the new order
of display for the parameters.
ENGINE SPEED
PERCENT LOAD AT CURRENT RPM
ENGINE OIL PRESSURE
ENGINE COOLANT TEMPERATURE
2
1
3
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN OFF
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC SCAN ON
GO TO 1-UP DISPLAY
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
ADJUST BACKLIGHT
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 32 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
Setup 4-Up Display
1. From the single or four engine parameter display touch
the “Menu Button”.
2. The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until the “Setup 4-
Up Display” is highlighted.
3. Once the “Setup 4-Up Display” menu item has been
highlighted touch the “Enter Button” to activate the
“Setup 4- Up Display” menu.
4. Touch the “Enter Button” to activate the “Use Defaults”
function. This action will reset the unit to the factory
default.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
ADJUST BACKLIGHT
SETUP 1-UP DISPLAY
SELECT UNITS
SETUP-4-UP DISPLAY
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
ADJUST BACKLIGHT
SETUP 1-UP DISPLAY
SELECT UNITS
SETUP-4-UP DISPLAY
5. The “Use Defaults” screen will be displayed during the
resetting period then will automatically return to the
“Setup 4- Up Display” menu.
6. Select the “4-Up Custom Setup” from the “4-Up Setup”
menu.
7. The quadrant with the backlit parameter value is the current
selected parameter. Use the “Arrow Buttons” to highlight
the parameter value in the quadrant you wish to place a
new parameter.
8. Touch the “Enter Button” and a list of parameters will appear.
USE DEFAULTS
CUSTOM SETUP
RESTORED TO
DEFAULTS
USE DEFAULTS
CUSTOM SETUP
USE DEFAULTS
CUSTOM SETUP
125°F
COOL TEMP
14.2 57 PSI
1000 RPM
BATT VOLT
ENG RPM
OIL PRES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
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.
10. Touch the “Enter Button” to change the selected
parameter in the quadrant to the new parameter.
11. Use the “Menu Button” to return to the “4-Up Custom
Setup” screen.
12. The parameter in the selected quadrant has changed
to the parameter selected in the previous screen.
13. Repeat the parameter selection process until all spaces
are filled.
14. Touch the “Menu Button” to return to the main menu.
15. Touch the “Menu Button” to exit the Main menu and
return to the engine parameter display.
Utilities
(information and troubleshooting)
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
2. The main menu will be displayed. Use the “Arrow Buttons”
to scroll through the menu until the “Utilities” is
highlighted.
3. Once the “Utilities” menu item has been highlighted, touch
the “Enter Button” to activate the “Utilities” functions.
ENGINE SPEED
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL PRESSURE
ENGINE HOURS
ENGINE OIL TEMPERATURE
3
1
4
2
The number to the right
of the parameter indicates
the quadrant in which it
is displayed.
1= Upper Left Quadrant
2 = Lower Left Quadrant
3 = Upper Right Quadrant
4 = Lower Right Quadrant
ENGINE SPEED
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL PRESSURE
ENGINE HOURS
ENGINE OIL TEMPERATURE
3
1
2
4
ENGINE SPEED
ENGINE COOLANT TEMPERATURE
BATTERY POTENTIAL
ENGINE OIL PRESSURE
ENGINE HOURS
ENGINE OIL TEMPERATURE
3
1
4
2
Note the number to
the right of the selected
parameter indicating that the
parameter is now assigned
to that display location
125°F
COOL TEMP
143°F
OIL TEMP 57 PSI
1000 RPM
ENG RPM
OIL PRES
125°F
COOL TEMP
143°F
OIL TEMP 57 PSI
1000 RPM
ENG RPM
OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
ADJUST BACKLIGHT
SETUP 1-UP DISPLAY
SELECT UNITS
SETUP-4-UP DISPLAY
125°F
COOL TEMP
143°F
OIL TEMP
57 PSI
1000 RPM
ENG RPM
OIL PRES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
125°F
COOL TEMP
143°F
OIL TEMP
57 PSI
1000 RPM
ENG RPM
OIL PRES
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
SETUP 1-UP DISPLAY
ADJUST BACKLIGHT
UTILITIES
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
SETUP 1-UP DISPLAY
ADJUST BACKLIGHT
UTILITIES
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 34 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
4. Touch “Select” to enter the “Gage Data” display. When
“Gage Data” is selected the PowerView will
communicate with the analog gages at a fixed rate of
38.4k Band, 8 data bits, no parity check, 1 stop bits,
half duplex.
5. Use the “Arrow Buttons” to scroll through the items or
touch “Menu” to return to the “Utilities” menu.
6. Touch “Menu Button” to return to the “Utilities” menu.
7. Use the “Arrows” to highlight Remove All Gages”. Touch
“Select” to clear gage data from memory. It takes a
moment to clear all gages.
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
MODBUS SETUP
FAULT CONVERSION
ADJUST BACKLIGHT
DEMO MODE ON
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
1ofx
ENGINE OIL PRESSURE
ADDRESS:20
SOFTWARE REVISION #:
ERRORS: NONE
1ofx
ENGINE OIL PRESSURE
CLEARING GAGES
PLEASE WAIT
8. When the gage data has cleared, the display
automatically returns to the “Utilities” menu. Scroll to
“Software Version”. Touch “Select” to view the software
version currently in the diagnostic display.
9. Touch “Menu” to return to “Utilities”. Highlight Fault
Conversion” using the “Arrows”. Touch “Select” to enter
the Fault conversion menu.
10. Use the “Arrows” to scroll to and highlight the desired
version then touch “Select”. An asterisk denotes which
version is currently selected.
NOTE: There are four (4) different methods for converting
fault codes. The diagnostic display always looks for J1939
Version 4 and can be set to read the code as one of three (3)
other J1939 versions if Version 4 is not being used. Most
engine ECU’s use Version 4, therefore in most cases
adjustment of this menu option will not be required.
Upon receiving an unrecognizable fault, change to a different
J1939 Version. If the fault SPN does not change when the
version is changed, the ECU generating the fault is using
Fault Conversion method 4. If the SPN number does not
change but is still unrecognizable, try changing to another
J1939 Version not yet used and continue to check the SPN
number.
SOFTWARE
VERSION
MURPHY: X.XX
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT CONVERSION
J1939 VERSION 1
J1939 VERSION 2
J1939 VERSION 3
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 35
1
11. Touch the “Menu” button to return to “Utilities” menu.
Touch the “Menu button again to return to the “Main”
menu.
MODBUS SETUP
1. Starting at the single or four engine parameter display,
touch the “Menu Button”.
2. The main menu will be displayed. Use the “Arrow
Buttons” to scroll through the menu until the “Utilities”
is highlighted, then touch “Enter”.
3. Once in the “Utilities” menu use the “Arrows” to scroll
through the menu until the “Modbus Setup” menu is
highlighted, then touch “Enter”.
4. Use the “Arrows” to scroll down to and highlight either
the “Slave Active or Master Active” modes. Touch the
“Enter” button to toggle between master and slave.
5. Use the “Arrows” to scroll to the “Serial Port” menu to
highlight it, then touch “Enter”.
6. Use the “Arrow” button to scroll to each selection to
configure the MODBUS values for your application.
7. When finished, touch “Menu” to return to the previous
screen.
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
SETUP 1-UP DISPLAY
ADJUST BACKLIGHT
UTILITIES
COOL
1800 RPM
01500 3000
TEMP
ENG RPM
98%
14.2 57 PSI
1000 RPM
LOAD RPM
BATT VOLT
ENG RPM
OIL PRES
ENGINE CONF
SETUP-4-UP DISPLAY
SELECT UNITS
STORED CODES
G
SETUP 1-UP DISPLAY
ADJUST BACKLIGHT
UTILITIES
GAGE DATA
REMOVE ALL GAGES
SOFTWARE VERSION
FAULT CONVERSION
MODBUS SETUP
USE FACTORY DEFAULT
SERIAL PORT SETUP
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
USE FACTORY DEFAULT
SOFTWARE VERSION
SLAVE ADDRESS SETUP
MASTER ACTIVE
SERIAL PORT SETUP
BAUD RATE
DATA BITS
STOP BITS
PARITY
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
PAGE 36 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
GLOSSARY (Troubleshooting information)
CANBUS FAILURE
Diagnostic Display has not received any CAN messages for at least 30 seconds.
NO DATA
Diagnostic Display has not received the particular message being displayed for at least 5 seconds.
NOT SUPPORTED
Diagnostic Display has received a message from the ECU stating the displayed message is not supported
DATA ERROR
Diagnostic Display has received an error message from the ECU for the displayed message.
EMPTY
No parameter selected for this 4- UP quadrant.
WAIT TO START PREHEATING
This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING
The ECU did not respond to the PowerView request.
NO GAGE DATA
The Diagnostic Display has no record of connected gages to the RS485 bus.
DISPLAY NOT VISIBLE
Press and hold the “Menu” button for approximately 3 seconds.
DCA-220SSJ/SSJU — DIAGNOSTIC DISPLAY
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 37
1
DCA-220SSJ/SSJU — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-220SSJ/SSJU
Generator Control Panel
(Figure 7).
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 50 Hz.
2. AC Ammeter – Indicates the amount of current the load
is drawing from the generator per leg selected by the
ammeter phase-selector switch.
3. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
4. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.
5. AC Voltmeter – Indicates the output voltage present at
the
U,V, and W Output Terminal Lugs
.
6. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
7. Main Circuit Breaker – This three-pole, 600A main
breaker is provided to protect the the
U,V, and W Output
Terminal Lugs
from overload.
Located behind the generator control panel is the
Generator
Control Box
. This box contains some of the necessary
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer (AVR)
■■
■■
■
Starter Relay
■■
■■
■
Current Transformer
■■
■■
■
Voltage Selector Switch
■■
■■
■
Three Phase Circuit Breaker
Figure 7. Generator Control Panel
Remember the
overcurrent
relay
monitors the current
flowing from the
U,V, and W
Output Terminal Lugs
to the
load.
In the event of a short circuit or over current condition, it will
automatically trip the 600 amp main breaker.
To restore power to the
Output Terminal Panel
, press the
reset
button on the overcurrent relay and place the
main
circuit breaker in the
closed
position (ON).
NOTE
PAGE 38 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Figure 8. Engine Operating Panel
DCA-220SSJ/SSJU — ENGINE OPERATING PANEL
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 activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
2. Panel Light Switch – When activated will turn on control
panel light.
3. Oil Pressure Gauge – During normal operation this
gauge be should read between 35 to 65 psi. (241~448
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
4. Water Temperature Gauge – During normal operation
this gauge be should read between 180° and 230°F. (82° C
and 110° C
5. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
6. Fuel Gauge - Indicates amount of diesel fuel available.
7. Tachometer – Indicates engine speed in RPM’s for 50
Hz operation. This meter should indicate 1500 RPM’s
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that
the generator has been in use.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 39
1
DCA-220SSJ/SSJU — ENGINE OPERATING PANEL
8. Engine Speed Switch – This switch controls the speed
of the engine (low/high).
9. Pre-Heat Lamp – When lit, indicates engine is in the
pre-heating mode (for starting during cold weather
operating conditiions). When lamp goes off engine is
ready for starting.
10. Warning Lamp – This lamp will illuminate when a critical
engine fault has occured.
11. Emergency Stop Lamp – This lamp will illuminate when
the emergency stop button has been pressed or a critical
engine fault has occured.
12. Emergency Stop Button – In the event of an
emergency, press this button to shutdown the generator.
13. Diagnostic Display – This display monitors crtical
engine functions. If any abnormal conditions occur, an
Active Fault Code will be displayed. This diagnostic
display can be located inside the control box.
A. MPEC Control Switch – This switch controls the
running of the unit. If this switch is set to the
OFF/RESET position, the unit will not run. When this
switch is set to the MANUAL position, the generator
will start immediately.
If the generator is to be connected to a building’s AC
power source via an automatic transfer switch
(isolation), place the switch in the AUTO position. In
this position, should an outage occur, the automatic
transfer switch (ATS) will start the generator
automatically via the generator’s auto-start contacts
connected to the ATS’s start contacts. Please refer to
your ATS installation manual for further instructions for
the correct installation of the auto-start contacts of the
generator to the ATS.
B. Low Oil Pressure – Indicates the engine pressure has
fallen below 15 psi. The oil pressure is detected using
variable resistive values from the oil pressure sending
unit. This is considered a
major
fault.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 239
°
F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a
major
fault.
D. Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles
with a 10 second duration. This is considered a
major
fault.
E. Overspeed Shutdown – Indicates the engine is running
at an unsafe speed. This is considered a
major
fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
Also the engine controller will shut down the engine in the
event of low oil pressure, high coolant temperature, low
coolant level, and loss of magnetic pickup. These conditions
can be observed by monitoring the LED status indicators on
the front of the controller module.
14. Auto On/Off Engine Controller (MPEC) –
This controller has a vertical row of status LED's (inset),
that when lit, indicate that an engine malfunction (fault)
has been detected. When a fault
has been detected the engine
controller will evaluate the fault
and all major faults will shutdown
the generator. During
cranking
cycle
, The MPEC will attempt to
crank the engine for 10 seconds
before disengaging.
If the engine does not engage (start) by the third attempt,
the engine will be shutdown by the engine controller’s
Over
Crank Protection
mode. If the engine engages at a speed
(RPM's) that is not safe, the controller will shutdown the
engine by initializing the
Over Speed Protection
mode.
PAGE 40 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Output Terminal Familiarization
The “
Output Terminal Panel
” (Figure 8) is provided with the
following:
■■
■■
■
Three (3) 100/200V output receptacles @ 50 amp
■■
■■
■
Three (3) Circuit Breakers @ 50 amps
■■
■■
■
Two (2) 100V GFCI receptacles @ 20 amp
■■
■■
■
Two (2) GFCI Circuit Breakers @ 20 amps
■■
■■
■
Five (5) Output Terminal Lugs ( U, V, W, O, Ground)
Output Terminal Panel
The
Output Terminal Panel
(Figure 9) shown below is located
on the right-hand side (left from control panel) of the generator.
Lift up on the cover to gain access to receptacles and terminal
lugs.
NOTE Terminal legs “O” and “Ground”
are considered
bonded grounds
.
Figure 9. Output Terminal Panel
DCA-220SSJ/SSJU — OUTPUT TERMINAL PANEL FAMILIARIZATION
AUX. POWER RECEPTACLES
100/200V, 50 AMPS
100 VAC, 20 AMP
GFCI RECEPTACLES
Y
X
W
CS-6369
TWIST-LOCK
CIRCUIT BREAKERS
FOR GFCI RECEPTACLES
RECEPTACLE
AND
CIRCUIT BREAKER
PANEL
MQPOWER
ACCESS DOOR
LIFT TO OPEN
HARD WIRE
HOOKUP PANEL
O
UVW
BLACK RED BLUE WHITE GREEN
1Ø AND 3Ø,
480 -120 VAC
OUTPUT TERMINALS
NEUTRAL
TERMINAL
GROUND
TERMINAL
CIRCUIT BREAKERS
FOR CS-6369 TWIST
LOCK RECEPTACLES
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 41
1
100 VAC GFCI Receptacles
There are two 100 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
voltage selector switch
position. Each receptacle is protected by a 20 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) of both
GFCI receptacles is dependent on the load requirements of
the U, V, and W output terminal lugs.
Pressing the
reset
button resets the GFCI receptacle after
being tripped. Pressing the
Test Button
(See Figure 10) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 10. G.F.C.I. Receptacle
Each auxilliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
Output Terminal Lugs
.
Turn the
voltage regulator control knob
(Figure 12) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will
increase
the voltage, turning the knob counter-
clockwise will
decrease
the voltage.
Figure 11. 100/200V Twist-Lock
Auxiliary Receptacles
DCA-220SSJ/SSJU — OUTPUT TERMINAL PANEL FAMILIARIZATION
Twist Lock Dual Voltage 100/200 VAC Receptacles
There are three 100/200V, 50 amp auxilliary twist-lock
(CS-6369) recepacles (Figure 11) provided on the output
terminal panel.These receptacles can
only
be accessed
when the voltage change-over board is configured for
three-
phase 240 operation.
Figure 12. Voltage Regulator Control Knob
Figure 13. Plastic Face Plate (Output Terminal Lugs)
Removing the Plastic Face Plate (Hard Wire Hookup Panel)
The
Output Terminal Lugs
are protected by a plastic face
plate cover (Figure 13). Un-screw the securing bolts and lift
the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
CS-6369
TWIST-LOCK
RECEPTACLES
SINGLE-PHASE
100/200 VAC
50 AMP OUTPUT
PAGE 42 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Figure 14. Connecting Loads
Connecting Loads
Loads can be connected to the generator by the
Ouput
Terminal Lugs
or the convienience receptacles (Figure 14).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a
3-pole, 600A
main
circuit breaker is provided. Make sure to
switch ALL circuit breakers to the OFF position prior to
starting the engine.
DCA-220SSJ/SSJU — OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
An
over current relay
(Figure 15) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
reset button
on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
Figure 15. Over Current Relay
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 43
1
DCA-220SSJ/SSJU — LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage,
frequency
,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
Motors and motor-driven
equipment draw much greater
current for starting than during
operation.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
If wattage is not given on the
equipment's name plate,
approximate wattage may be
determined by multiplying
nameplate voltage by the
nameplate amperage.
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
■■
■■
■
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
■■
■■
■
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
■■
■■
■
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
NOTE
WATTS = VOLTAGE x AMPERAGE
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
NOTE
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
NOTE
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.
DANGER - ELECTRICAL SYSTEM HAZARDS
daoLyBrotcaFrewoP.5elbaT
daoLfOepyTrotcaFrewoP
srotomnoitcudniesahp-elgniS57.0-4.0
tnecsednacni,sretaehcirtcelE
spmal 0.1
spmalyrucre
m,spmaltnecseroulF9.0-4.0
noitacinummoc,secivedcinortcelE
tnempiuqe 0.1
slootrewopnommoC8.0
Table 6. Cable Selection (50 Hz, Single Phase Operation)
Current
in
Amperes
Load in Watts Maximum Allowable Cable Length
At 100
Volts
At 200
Volts #10 Wire #12 Wire #14 Wire #16 Wire
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
CAUTION: Equipment damage can result from low voltage
PAGE 44 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — GENERATOR OUTPUTS
Generator Amperage
Tables 8 and 9 describe the generator’s current output capa-
bility for both 1Ø-phase and 3Ø phase applications.
Generator Output Voltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by apply-
ing jumpers (6) to the
voltage change-over board
(Figure 15).
To obtain some of the voltages as listed in Table 6 (see
below) will require a fine adjustment using the
voltage regu-
lator
(VR)
control knob
located on the control panel.
Voltage Change-Over Board
The
voltage change-over board
(Figure 16) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
CAUTION - CHANGING VOLTAGES
NEVER attempt to place jumper plates on the
voltage
change-over board
while the generator is in operation.
There exist the possibility of
electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death
!
Figure 16. Voltage Change-Over Board
Table 7. Voltages Available
Three Phase
(Switchable) 200V 220V 400V 440V
Single Phase
(Switchable) 115V 127V 230V 254V
Table 8. Generator Ampere Ratings — 1Ø
kW 100V 200V
16 160 80
36 360 180
56 560 280
76 760 380
96 960 480
116 1160 580
136 1360 680
156 1560 780
176 (Max) 1760 880
Table 9. Generator Ampere Ratings — 3Ø
KVA 200V 400V
20 57 29
36 103 51
56 161 80
68 196 98
100 288 144
120 346 173
144 415 207
176 508 254
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 45
1
Maximum Amps
Table 10 shows the
maximum
amps the generator can pro-
vide. DO NOT exceed the maximum amps as listed.
How to Read the Output Terminal Gauge.
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
When the voltage change-over board (Figure 16) is jumpered
for 3Ø, 240V operation place the
AC Voltmeter Change-
Over
Switch
(Figure 17) to the W-U position and the
AC
Ammeter Change-Over Switch
(Figure 19) to the U or W
position. Use the AC voltmeter or AC ammeter (Figures 18
and 20) to read the output on the selected leg of the UVWO
terminals.
Figure 17. AC Voltmeter
Change-Over Switch
Figure 18. AC Voltmeter Gauge
(Volt reading on W-U Lug)
Figure 20. AC Ammeter
(Amp reading on U lug)
Figure 19. AC Ammeter
Change-Over Switch
The
ammeter
gauge will only
show a reading when the
Output Terminal Lugs
are
connected to a load and in use.
NOTE
DCA-220SSJ/SSJU — GENERATOR OUTPUTS/ GAUGE READING
Table 10. Generator Maximum Amps
Model DCA-220SSJ/SSJU
Rated Voltage Maximum Amps
Single Phase
100 Volt 466 amps (4 wire)
Single Phase
200 Volt 233 amps (4 wire)
Three Phase
200 Volt 508 amps
Three Phase
400 Volt 254 amps
PAGE 46 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Figure 21. Voltage Change-Over Board
200V Configuration
UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are de-
pendent on the placement of the jumpers plates (6) on the
Voltage Change-Over Board
and the adjustment of the
Voltage Regulator Control Knob
.
Remember the voltage change-over board determines the
range
of the output voltage and can be configured in two
different positions that provide 6 different output voltages at
the UVWO output terminals. The generator is shipped from
the factory in the 240V configuration. The voltage regulator
(VR) allows the user to increase or decrease the selected
voltage.
3Ø-200V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 240V operation
as shown in Figure 21.
Figure 22. UVWO Terminal Lugs
3Ø-20 0V Connections
2. Connect the load wires to the UVWO terminals as shown
in Figure 22.
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
Figure 23. Voltage Regulator Knob
1Ø-200V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21 .
2. Connect the load wires to the UVWO terminals as shown
in Figure 24.
Figure 24. UVWO Terminal Lugs
1Ø-200V Connections
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
THREE-PHASE
200 VAC (LOAD CONNECTIONS)
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
200V 200V
200V
SINGLE-PHASE
200 VAC (LOAD CONNECTIONS)
Figure 25. UVWO Terminal Lugs
1Ø-115V Connections
1Ø-139V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as shown
in Figure 25.
DCA-220SSJ/SSJU — OUTPUT TERMINAL PANEL CONNECTIONS
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
115V
115V
SINGLE-PHASE
115 VAC (LOAD CONNECTIONS)
115V
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 47
1
DCA-220SSJ/SSJU — OUTPUT TERMINAL PANEL CONNECTIONS
2. Connect the load wires to the UVWO terminals as shown
in Figure 27.
3Ø-400V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 480V operation
as shown in Figure 26. This configuration uses 6 jumper
plates in 3 different positions. Remember there are 2
jumper plates at every position. Every jumper plate
must
be used.
Figure 26. Voltage Change-Over Board
400V Configuration
Figure 27. UVWO Terminal Lugs
3Ø-400V Connections
1Ø-400V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
2. Connect the load wires to the UVWO terminals as shown
in Figure 28.
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
THREE-PHASE
400 VAC (LOAD CONNECTIONS)
1Ø-230V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 400V operation as shown in Figure 26.
2. Connect the load wires to the UVWO terminals as shown
in Figure 29.
Figure 29. UVWO Terminal Lugs
1Ø-230V Connections
ALWAYS make sure that the
connections to the UVWO
terminals are
secure
and tight.
The possibility of arcing exists,
that could cause a fire.
NOTE
Figure 28. UVWO Terminal Lugs
1Ø-400V Connections
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
400V 400V
400V
SINGLE-PHASE
400 VAC (LOAD CONNECTIONS)
O
UVW
BLACK RED BLUE WHITE GREEN
GROUND
CONNECTION
BE USED
AT ALL TIMES
MUST
230V
230V
SINGLE-PHASE
230 VAC (LOAD CONNECTIONS)
230V
PAGE 48 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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 John Deere Engine Owner's Manual. Oil should be
warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
■■
■■
■
API Service Classification CC/SC
■■
■■
■
API Service Classification CC/SD
■■
■■
■
API Service Classification CC/SE
■■
■■
■
API Service Classification CC/SF
Circuit Breakers
To protect the generator from an overload, a 3-pole, 600 amp,
main
circuit breaker is provided to protect the
U,V, and W
Output Terminals
from overload. In addition two single-pole,
20 amp
GFCI
circuit breakers are provided to protect the
GFCI receptacles from overload. Three 50 amp
load
circuit
breakers have also been provided to protect the auxiliary
receptacles from overload. Make sure to switch ALL circuit
breakers to the OFF position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
and verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 9 for proper
selection of engine oil.
Figure 31. Internal Fuel Tank System
Refilling the Fuel System
Fuel Check
This generator has an internal fuel tank located inside the
trailer frame and may also be equipped with an environmental
fuel tank (Figure 31).
ALWAYS
fill the fuel tanks with clean
fresh
#2 diesel fuel.
DO NOT fill the fuel tanks beyond their
capacities.
Pay attention to the fuel tank capacity when replenishing
fuel.The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
CAUTION - REFUELING THE GENERATOR
Fuel spillage on a
hot
engine can cause a
fire
or
explosion
.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
DANGER - EXPLOSION/FIRE HAZARDS
ENVIRONMENTAL
FUEL TANK
(
OPTION
)
WHISPERWATT
220
TRAILER MOUNTED
FUEL TANK
(OPTION)
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 49
1
DCA-220SSJ/SSJU — PRE-SETUP
Refueling Procedure:
1. Level Tanks – Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
Figure 32. Only Fill on Level Ground
ONLY! use
#2 diesel fuel
when
refueling.
NOTE
3. NEVER overfill fuel tank – It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait for
fuel to rise in filler neck (Figure 34).
Figure 34. Full Fuel Tank
Figure 35. Fuel Expansion
3. Open cabinet doors on the “right side” of the generator
(from generator control panel position). Remove fuel cap
and fill tank (Figure 33).
Figure 33. Fueling the Generator
ALWAYS
place trailer on firm level ground before refueling
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
CAUTION - REFUELING THE GENERATOR
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
WARNING - RESPIRATORY HAZARDS
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 35).
CAUTION - REFUELING THE GENERATOR
PAGE 50 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the "H" and the "L" markings.
Operation Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
negative
battery terminal disconnected.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the John Deere Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Deere Engine Owner's Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 36) when depressed with the thumb as shown
below.
Figure 36. Fan Belt Tension
DCA-220SSJ/SSJU — PRE-SETUP
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be
less than 50%.
NOTE
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of
hot!
coolant exists which
can cause severe burns.
WARNING - BURN HAZARDS
NEVER place hands near
the belts or fan while the
generator set is running.
CAUTION - ROTATING PARTS
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serutarepmeTgnitarepO
%loV
ezeerF-itnA
tnioPgnizeerF
C°F°
0573-43-
Coolant (Antifreeze)
John Deere recommends Antifreeze/Summer Coolant for use
in thier engines, which can be purchased in concentrate (and
mixed with 50% demineralized water) or pre-diluted. See
the John Deere Engine Owner's Manual for further details
Table 12. Coolant Capacity
Engine and Radiator 64 Gal (60 liters)
Reserve Tank 2 Quarts (1.9 liters)
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 MANUAL or AUTO position. ALWAYS make sure that
the
MPEC Control Switch
is in the OFF/RESET position
when connecting the battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
Figure 37. Battery Connections
ALWAYS
disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
Alternator
The polarity of the alternator is negative grounding type. When
an inverted circuit connection takes place, the circuit will be
in short circuit instantaneously resulting the alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrision and damage the
alternator.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
If any hose (
fuel
or
oil
) lines are defective replace them
immediately.
If the battery cable is connected
incorrectly, electrical damage to the
generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
NOTE
Battery
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are not
properly maintained. Add only distilled water when
replenishment is necessary.
DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions.
Always
keep the terminals firmly tightened.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 37) are properly
connected to the battery terminals as shown below. The Red
Cable is connected to the positive terminal of the battery,
and the Black Cable is connected to the negative terminal
of the battery.
CAUTION - BATTERY SERVICING SAFETY
CAUTION - BATTERY SERVICING SAFETY
PAGE 52 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Starting (Manual)
1. Place the engine speed switch (Figure 41) in the “
LOW
”
(down) position
Figure 42. MPEC Control Switch
(Manual Position)
DCA-220SSJ/SSJU — GENERATOR START-UP PROCEDURE (MANUAL)
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating
.
Direct exhaust away from nearby personnel.
Before Starting
Figure 40. Engine Enclosure Doors
2. Place the
main, G.F.C.I.,
and
aux.
circuit breakers
(Figure 39) in the OFF position prior to starting the engine.
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
3. Make sure the the
voltage change-over board
has
been configured for the desired output voltage.
4. Connect the load to the
receptacles
or
the
output
terminal lugs
as shown in Figure 14. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
5. The output terminal lugs are protected by a plastic cover.
Remove this cover to gain access to the terminals.
Tighten terminal nuts securely to prevent load wires from
slipping out.
6. Close all engine enclosure doors (Figure 40).
CAUTION - LETHAL EXHAUST HAZARD
2. Place the
MPEC Control Switch
in the MANUAL
position to start the engine (Figure 42). Observe that the
Warning and Emergency Stop lamps on the Engine
Operating Panel are lit during the initial starting of the
engine. If no abnormal conditions exists, both lamps will
turn off.
Figure 41. Engine Speed Switch (Low)
NEVER!
manually start the engine with the
main
,
GFCI
or
auxiliary
circuit breakers in the ON (closed) position.
WARNING - STARTING THE GENERATOR
The Engine Control Unit (ECU) used with this generator
diagnosis engine faults that arise with the the engine control
system and the engine itself. Engine faults can be determined
by viewing the Diagnostic Trouble Codes (Active Fault Codes)
which are displayed on the Diagnostic Display Panel located
inside the Control Box.
1. Before starting the engine, make sure the diagnostic
switch (Figure 38) on the Diagnostic Display Panel
Assembly is in the “OFF” position.
Figure 38. Diagnostic Switch (OFF poistion)
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 53
1
10.Verify that the Engine Running
status LED on the MPEC unit
(Figure 45) is ON (lit) after the
engine has been started.
3. If any abnormalities exists, the Warning and
Emergency Stop lamps on the Engine Operating Panel
will be lit.
4. Place the
MPEC Control Switch
(Figure 42) in the
OFF/RESET position.
5. Place the Diagnostic ON/OFF switch in the ON
position. Verify that an Active Fault Code message is
being displayed (Diagnostic Display Panel). The fault
code message will continued to be displayed until the
fault has been corrected. Figure 43 shown below is a
typical example of an active fault code message (Low
Radiator Coolant).
Figure 44. Engine Speed Switch (High)
When the MPEC Control switch is
placed in the manual position,
preheating of the glow plugs will begin
automatically and the preheat lamp
will stay lit until the
glow plugs are warmed. When the preheat
lamp goes off this signals the completion of
the preheating cycle and the starting of the
engine.
NOTE
Preheat Lamp
9. If the engine is running smoothly, place the engine
speed switch (Figure 44) in the “
HIGH
” (up) position.
Figure 43. Active Fault Code Message
6. In a situation where several engine problems occur
simultaneously, the word “MORE” appears above the
arrow buttons indicating that there are more fault codes
that need to be viewed. Use the arrow buttons to scroll
to the next active fault code.
If desired, the type of fault code, cause of error and
the countermeasures of the error can be referenced in
a separate engine operator’s manual.
7. Before the engine can be started, the engine fault must
be corrected. Also observe that there are no active
fault codes displayed on the diagnostic panel. If no
fault codes are displayed, place the diagnostic switch
in the OFF position.
13. The generator's AC-voltmeter (Figure 47) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 48) to increase or decrease the
desired voltage.
Figure 46. Frequency Meter (Hz)
12. The generator's frequency meter (Figure 46) should be
displaying the 50 cycle output frequency in HERTZ.
Figure 45. Engine Running LED (ON)
11. Observe that the Warning and Emergency Stop lamps
on the Engine Operating Panel are OFF.
8. To restart the engine due to error codes, place the
MPEC
Control Switch
in the MANUAL position (Figure 42)
Figure 47. Voltmeter
DCA-220SSJ/SSJU — GENERATOR START-UP PROCEDURE (MANUAL)
PAGE 54 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
When the generator is set in the
AUTO 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.
NOTE
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.
DANGER - ELECTRICAL SYSTEM HAZARDS
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
CAUTION - BACKUP GENERATOR USE
Figure 53. Main, Aux. and GFCI
Circuit Breakers (ON)
18. Place the
main
,
GFCI
, and
aux
. circuit breakers in the
ON position (Figure 53).
19. Observe the generator's ammeter
(Figure 54) and verify it reads the
anticipated amount of current with
respect to the load. The ammeter
will only display a current reading if
a load is in use. Figure 54. Ammeter
(Load)
20. The generator will run until manually stopped or an
abnormal condition occurs.
DCA-220SSJ/SSJU — GENERATOR START-UP PROCEDURE (MANUAL)
Figure 48. Voltage Adjust Control Knob
Figure 49. Ammeter
(No Load)
14. The ammeter (Figure 49) will
indicate
zero amps
with no load
applied. When a load is applied, the
ammeter will indicate the amount of
current that the load is drawing from
the generator.
Figure 52. Engine
Tachometer Gauge
17. The
tachometer gauge
(Figure 52)
will indicate the speed of the engine
when the generator is operating.
Under normal operating conditions
this speed is approximately 1800
RPM’s.
16. The
coolant temperature gauge
(Figure 51) will indicate the
coolant temperature. Under
normal operating conditions the
coolant temperature should be
between 180~230°F (82~110 °C)
Green Zone
.
Figure 51. Coolant
Temperature Gauge
15. The engine oil pressure gauge
(Figure 50) will indicate the oil
pressure of the engine. Under
normal operating conditions the oil
pressure is approximately 35 to 65
psi. (241~448 kPa). When starting
the generator
Figure 50. Oil
Pressure Gauge
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 55
1
1. Perform 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 (start at step 5).
Figure 55. MPEC Control Switch (AUTO)
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
WARNING - AUTO MODE MAINTENANCE
DCA-220SSJ/SSJU — GENERATOR START-UP PROCEDURE (AUTO MODE)
When the MPEC
Control Switch
is placed in the AUTO position,
the engine glow plugs will be
warmed and the engine will start
automatically.
NOTE
When starting generator in AUTO mode use the "
Manual
Start-up" procedure except where noted (see below).
CAUTION - ENGINE SPEED SWITCH
The
Engine Speed Switch
must be set to the “High”
position when running in the
Auto-Start
mode. Failing to
set the switch in the proper position can result in damage
to your generator when it turns on. 3. Place the
MPEC Control Switch
(Figure 55) in the AUTO
position
Figure 54. Engine Speed Switch (High)
PAGE 56 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Normal Shutdown Procedure
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 39 to the OFF position.
2. Place the engine speed switch (Figure 56) in the “
LOW
”
(down) position.
Figure 57. MPEC Control Switch (Off/Reset)
5. Verify that the
all
status LED on the MPEC display
are OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occured during operation.
Emergency Shutdown Procedure
1. To shut-down the engine in the event of an emergency,
push the
Emergency Stop Button
(Figure 58).
2. Switch the
MAIN
,
GFCI
and
LOAD
(Figure 38) circuit
breakers to OFF position.
DCA-220SSJ/SSJU — GENERATOR SHUT-DOWN PROCEDURES
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the
MPEC Control Switch
(Figure 57) to the
OFF/RESET position.
Figure 56. Engine Speed Switch (Low)
NEVER stop the engine suddenly except in an emergency.
WARNING -
SHUTTING DOWN THE GENERATOR
Figure 58. Emergency Stop Button
ALWAYS make sure the diagnostic switch is placed in the
OFF position before attempting to shut down the generator.
The OFF/RESET switch on the MEC controller will not
shut down the generator if the diagnostic switch is left in
the ON position.
CAUTION -
DIAGNOSTIC SWITCH
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, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more
frequently
if these conditions exists.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations).
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
General Inspection
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel,
oil, and coolant leaks. Use Table 14 as a general maintenance
guideline Engine Side (Refer to the Engine Instruction
Manual)
Air Cleaner
Every 250 hours: Remove air cleaner element and clean the
heavy duty paper element with light spray of compressed
air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator is attached to the air cleaner. When the air
cleaner element is clogged, air intake restriction becomes
greater and the dust indicator signal shows RED meaning
the element needs changing or service. After changing the
air element, press the dust indicator button to reset the
indicator.
ECNANETNIAM/NOITCEPSNI.41ELBAT
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ENIGNE
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PAGE 58 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
Flushing Out Radiator and Replacing Coolant
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open the
radiator cap while draining. Remove the overflow tank
and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO NOT
clean radiator core with any objects, such as a
screwdriver.
Tighten both cocks and replace the overflow tank.
Replace with coolant as recommended by the engine
manufaturer.
Close radiator cap tightly.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure. See the
John Deere
Engine Manual
for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 31.
Replacing Oil Filter
Remove the old oil filter.
Apply a film of oil to the gasket on the new oil filter.
Install the new oil filter.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check
for leaks before adding more oil if needed. Clean
excessive oil from engine.
Allow engine to
cool
when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
WARNING - BURN HAZARDS
Replacing Fuel Filter
Replace the fuel filter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it. Securely fasten
the fuel strainer cap so that fuel will not leak. Check the fuel
strainer every 200 hours of operation or once a month.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 59
1
DCA-220SSJ/SSJU — MAINTENANCE (HEATER/CHARGER)
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger
.
NOTE
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
PAGE 60 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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 (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 16 and Figure 59 for lug nut tightening
and sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches. Please note that some trailers have a double
axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
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.
Trailer Maintenance
This section is intended to provide the user with generic
trailer service and maintenance information. The service and
maintenance guidelines referenced in this section refer to a
wide range of trailers.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
The definitions below describe some of the major components
of a typical trailer that would be used with the DCA-220SSJ/
SSJU
Whisperwatt
™
Generator.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR) is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
5. Frame Width - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
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 cracks, kinks, or blockage.
Figure 60. Hydraulic Brake Components
Brakes
Trailer brakes should be inspected the
first 200 miles
of
operation. This will allow the brake shoes and drums to seat
properly. After the first 200 mile interval, inspect the brakes
every 3,000 miles
. If driving over rough terrain, inspect the
brakes more frequently.
Figure 59 displays the major hydraulic surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 8 and Table 15 as listed below:
Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
star wheel of the adjuster assembly to expand the brake
shoes.
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6. Adjust, rotate the star wheel in the opposite direction
until the wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
8. Repeat steps 1 through 7 on the remaining brakes.
Actuator
Hydraulic surge braking requires the installation of an actuator
at the tongue of the trailer. Remember the
surge
or
push
of
the trailer toward the tow vehicle automatically synchronizes
the trailer brakes with the tow vehicle brakes. As the trailer
pushes against the tow vehicle the actuator telescopes
together and applies force to the master cylinder, supplying
hydraulic pressure to the trailer brakes.
Periodically check and test the surge “
actuator
” to make
sure that it is functioning correctly. Never use an undersize
actuator.
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PAGE 62 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
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.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are
hot!
. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The
leaf suspension
springs and associated components
(Figure 61) should be visually inspected every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
Figure 61. Major Suspension Components
DCA-220SSJ/SSJU — MAINTENANCE (TRAILER)
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.
CAUTION - REPAIRING TRAILER WHEELS
ALWAYS
wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - EYESIGHT HAZARD
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TLOB-U"8/353-XAM03-NIM
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TLOB-U"2/106-XAM54-NIM
SHACKLE BOLT
SPRING EYE BOLT
SNUG FIT ONLY
.
PARTS MUST ROTATE FREELY
.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT
-
BOLT ASSEMBLY
.
SHOULDER TYPE
SHACKLE BOLT
05-XAM03-NIM
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 Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (see Figure 62). DO NOT
torque the wheel lug nuts all the way down. Tighten each
lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
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"5152-0206-05021-09
"6152-0206-05021-09
PAGE 64 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — TRAILER WIRING DIAGRAM
Figure 63. Trailer/Towing Vehicle Wiring Diagram
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 65
1
DCA-220SSJ/SSJU — GENERATOR WIRING DIAGRAM
Figure 64. Generator Wiring Diagram
PAGE 66 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — ENGINE WIRING DIAGRAM
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
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company's business office or service plant.
DCA-220SSJ/SSJU — TROUBLESHOOTING (GENERATOR)
GNITOOHSELBUORTROTARENEG.91ELBAT
MOTPMYS MELBORPELBISSOP NOITULOS
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PAGE 68 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor
Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.
)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT
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DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 69
1
NOTE PAGE
PAGE 70 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — EXPLANATION OF CODE IN REMARKS COLUMN
NOTE
When ordering a part that has more
than one item number listed, check
the remarks column for help in
determining the proper part to order.
QTY. Column
Numbers Used - Item quantity can be indicated by a number,
a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other parts
that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed to
describe the item can also be shown.
Assembly/Kit
- All items on the parts list with the same unique
symbol will be included when this item is purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
Serial Number Break
- Used to list an effective serial number
range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use
- Indicates that the part is used
only with the specific model number or model number variant
listed. It can also be used to show a part is NOT used on a
specific model or model number variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally”
- Indicates that the part can be
purchased at any hardware shop or made out of available
items. Examples include battery cables, shims, and certain
washers and nuts.
“Not Sold Separately”
- Indicates that an item cannot be
purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available for
sale through Multiquip.
The following section explains the different symbols and remarks
used in the Parts section of this manual. Use the help numbers
found on the back page of the manual if there are any questions.
NO. Column
Unique Symbols - All items with same unique symbol
(*, #, +, %, or >) in the number column belong to the same
assembly or kit, which is indicated by a note in the “Remarks”
column.
Duplicate Item Numbers - Duplicate numbers indicate
multiple part numbers are in effect for the same general item,
such as different size saw blade guards in use or a part that
has been updated on newer versions of the same machine.
PART NO. Column
Numbers Used - Part numbers can be indicated by a number,
a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a part
that has not been assigned a formal part number at time of
publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will be
clarified in the “Remarks” Column.
Sample Parts List:
NO. PART NO. PART NAME QTY.REMARKS
1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/*
2*WASHER, 1/4 IN. ...........
NOT SOLD SEPARATELY
2*12347 WASHER, 3/8 IN. .... 1 ....
MQ-45T ONLY
3 12348 HOSE .................... A/R .. MAKE LOCALLY
4 12349 BEARING ................ 1.... S/N 2345B AND ABOVE
The contents and part numbers listed in the parts section are
subject to change
without notice
. Multiquip does not
guarantee the availibility of the parts listed.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 71
1
DCA-220SSJ/SSJU — SUGGESTED SPARE PARTS
Part number on this Suggested Spare Parts list
may supercede/replace the P/N shown in the text
pages of this book.
NOTE
DCA-220SSJ/SSJU WHISPER WATTGENRATOR
W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE
1 TO 3 UNITS
Qty.P/N Description
1 ......... M4310500803 ..... HOSE, RADIATOR UPPER
1 ......... M4310500903 ..... HOSE, RADIATOR LOWER
1 ......... 060202011062 .... RADIATOR CAP
1 ......... 0845500104 ........ FUEL CAP
1 ......... 0602015230 ........ V-BELT SET, FAN
1 ......... 0602122272 ........ UNIT, OIL PRESSURE
1 ......... 0602122281 ........ SWITCH, OIL PRESSURE
1 ......... 0602123282 ........ TEMP SENSOR UNIT
1 ......... 0602123261 ........ SWITCH, TEMPERATURE SENSOR
3 ......... 0810105400 ........ FILTER, FUEL, FUEL TANK
6 ......... 0602042596 ........ FILTER, FUEL PRIMARY
6 ......... 0602042597 ........ FILTER, FUEL FINAL
6 ......... 0602041292 ........ FILTER, OIL CARTRIDGE
3 ......... 0602046617 ........ ELEMENT AIR OUTER
3 ......... 0602046618 ........ ELEMENT AIR INNER
1 ......... 0601808803 ........ CIRCUIT BREAKER 1P 20A
1 ......... 0601808804 ........ CIRCUIT BREAKER 2P 50A
2 ......... LY2DUS12VDC ... RELAY
PAGE 72 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU — GENERATOR ASSY.
GENERATOR ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 73
1
DCA-220SSJ/SSJU — GENERATOR ASSY.
GENERATOR ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 C1110000002 ROTOR ASSEMBLY .................................. 1 ............. INCLUDES ITEMS W/*
1-1*FIELD ASSEMBLY 1
1-2*0601842334 RESISTOR, 80W 100K OHM 1
1-3*0601823282 RECTIFIER, RM50TC- 24 1
1-4*0018205020 HEX. SOCKET HEAD CAP SCREW 2
1-4A 0040005000 SPRING WASHER 2
1-4B 0041205000 PLAIN WASHER 2
1-5 8171070002 FAN 1
1-6 8171611003 COUPLING DISK 9
1-7 C1164200004 WASHER, COUPLING HUB 1
1-8 8171015003 BALANCING PLATE .................................. 1 ............. PURCHASE ITEM 1-11 AS A SET
1-9 0012116045 HEX. HEAD BOLT 8
1-10 0042616000 SPRING WASHER 8
1-11 0601000209 BALANCING WEIGHT KIT 1
1-12 C1112500004 BEARING FLANGE 1
1-13 0071906314 BEARING, 6314DDU C3 1
2 M4163400003 COUPLING RING 1
3 0343206120 HEX. HEAD BOLT 8
4 0043606000 SPRING WSHER 8
5 0012112040 HEX. HEAD BOLT 8
6 0042512000 SPRING WASHER 8
7 C1130100103 STATOR ASSEMBLY ................................. 1............. INCLUDES ITEMS W/#
7-1# 0226100420 RUBBER SEAL 1
7-2# 8171323004 CLAMPER 1
7-3# 0223300120 RUBBER SEAL 1
7-4# 8171323103 CLAMPER 1
7-5# 0221200300 RUBBER SEAL 1
7-6# 0010110035 HEX. HEAD BOLT 2
7-7# 0041210000 PLAIN WASHER 2
7-8# C1132200003 COVER 1
7-9# 0226000510 RUBBER SEAL 1
7-10# 0225000470 RUBBER SEAL 1
7-11# 0017106016 HEX. HEAD BOLT 6
7-12# 0601850144 GROMMET 1
8 C1154999992 END BRACKET 1
9 C1138000003 FIELD ASSEMBLY, EXCITER 1
PAGE 74 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
GENERATOR ASSY.
DCA-220SSJ/SSJU — GENERATOR ASSY. (CONT.)
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 75
1
GENERATOR ASSY. (CONT.)
NO. PART NO. PART NAME QTY.REMARKS
10 0012110065 HEX. HEAD BOLT 4
10A 0042610000 SPRING WASHER 4
10B 0041210000 PLAIN WASHER 4
11 0017112045 HEX. HEAD BOLT 6
12 C1154400004 COVER, BEARING 1
13 C1154300004 GASKET, BEARING 1
14 0010106060 HEX. HEAD BOLT 4
14A 0040006000 SPRING WASHER 4
14B 0041206000 PLAIN WASHER 4
15 C1154400103 SUCTION COVER 1
16 0017106016 HEX. HEAD BOLT 8
17 0343205150 HEX. HEAD BOLT 12
18 0043605000 SPRING WASHER 12
19 C1132300114 COVER, FAN 1
20 0010106030 HEX. HEAD BOLT 1
20A 0041206000 PLAIN WASHER 1
20B 0600815000 NUT 1
21 0605000012 RUBBER SUSPENSION 2
22 0030020000 HEX. NUT 4
22A 0040020000 SPRING WASHER 4
23 0070506907 BEARING, 6907ZZ 1
DCA-220SSJ/SSJU — GENERATOR ASSY. (CONT.)
PAGE 76 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 77
1
DCA-220SSJ/SSJU— CONTROL PANEL ASSY.
CONTROL PANEL ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 M4223000303 CONTROL PANEL 1
2 M4223000404 CONTROL PANEL 1
2-1 0222100100 RUBBER SEAL 2
2-2 0222100165 RUBBER SEAL 2
3 0605011211 PIN 2
4 0016908035 HEX. HEAD BOLT 4
5 0601807642 FREQUENCY METER, 45 ~65HZ 240V 1
6 0601808992 AC AMMETER, 0~400A 0~800A 1
7 0601801040 CHANGE- OVER SWITCH, AMMETER 1
8 0601800275 AC VOLTMETER, 0~600V 1
9 0601801041 CHANGE- OVER SWITCH, VOLTMETER 1
10 0601840073 RHEOSTAT (VR), 2W 1K OHM 1
11 0601840121 KNOB 1
12 0602202593 CONTROLLER, ECU 1
13 0027104035 MACHINE SCREW 2
13A 0207004000 HEX. NUT 2
14 0601831340 SWITCH 1
15 0601831395 ENGINE SPEED SWITCH 1
16 0602120096 TACHOMETER 1
17 0602122098 OIL PRESSURE GAUGE 1
18 0602122272 OIL PRESSURE UNIT 1
19 0602123092 WATER TEMPERATURE GAUGE 1
20 0602123263 WATER TEMPERATURE UNIT 1
21 0602121081 CHARGING AMMETER 1
22 0602125090 FUEL GAUGE 1
23 0602103092 ALARM LAMP 3
23A 0601810245 BULB, DC 18V 3
24 0601810160 PANEL LIGHT, DC 12V 1
24A 0601810213 BULB 1
25 0207004000 HEX NUT 2
26 0601831330 PANEL LIGHT SWITCH 1
27 0601831557 EMERGENCY STOP BUTTON 1
28 M9220100004 SET SCREW 2
28A 0080200007 SNAP RING 2
29 M4246700304 WIRE HARNESS, GENERATOR 1
30 M4357200102 WIRE HARNESS, ENGINE
PAGE 78 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— CONTROL BOX ASSY.
CONTROL BOX ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 79
1
DCA-220SSJ/SSJU— CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 M4213000102 CONTROL BOX 1
2 0601809667 CURRENT TRANSFORMER, 400/5A 3
3 0027106016 MACHINE SCREW 6
4 0601870422 CIRCUIT BREAKER, 600A 1
5 0601815168 REAR CONNECTOR KIT 1
6 M4273000003 TERMINAL BOARD, VOLTAGE CHANGE- OVER 1
7 M4276400004 CHANGE TERMINAL 10
8 0017106025 HEX. HEAD BOLT 20
9 M4276200004 TERMINAL PLATE 3
10 M4276300004 CHANGE- OVER PLATE 6
11 M4276100004 TIE BOLT 13
12 M9220100104 TIE BOLT 13
13 0040010000 WASHER, LOCK 26
14 0041410000 WASHER, FLAT 26
15 0016908030 HEX. HEAD BOLT 4
16 0601820625 AUTOMATIC VOLTAGE REGULATOR 1
17 0027105016 MACHINE SCREW 4
18 0601820847 OVER CURRENT RELAY 1
19 0601820848 OVER CURRENT RELAY 1
20 0027104016 MACHINE SCREW 2
20A 0207004000 HEX. NUT 2
21 M4260600304 BRACKET, DIAGNOSTIC GAUGE 1
22 0016908020 HEX. HEAD BOLT 2
23 0602120690 POWER VIEW 1
24 0601831330 DIAGNOSTIC SWITCH 1
25 0601813977 RECEPTACLE 1
25A 0601812891 DUST CAP 1
25B 0601812890 STRAIN RELIEF 1
26 M4270500003 SET PANEL, ELECTRIC PARTS 1
27 0016908020 HEX HEAD BOLT 4
28 0602202592 STARTER RELAY 1
29 0027106016 MACHINE SCREW 2
30 LY2DUS12VDC RELAY ....................................................................... 1.......... REPLACES P/N 0601827656
30A PTF08A BASE ......................................................................... 1.......... REPLACES P/N 0601823109
30B PYCA1 CLIP, .......................................................................... 2.......... REPLACES P/N 0601824400
31 0027104020 MACHINE SCREW 2
32 0601821370 RECTIFIER, DE45 ..................................................... 2.......... REPLACES P/N 0601823240
33 0027104020 MACHINE SCREW 2
34 M4260600404 BRACKET, RESISTOR UNIT 1
35 0016906016 HEX HEAD BOLT 2
36 M4266600004 RESISTOR UNIT 1
37 020106050 HEX NUT ................................................................... 1.......... REPLACES P/N 0030006000
PAGE 80 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
CONTROL BOX ASSY. (CONT.)
DCA-220SSJ/SSJU— CONTROL BOX ASSY. (CONT)
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 81
1
DCA-220SSJ/SSJU— CONTROL BOX ASSY. (CONT)
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY.REMARKS
38 0027106020 MACHINE SCREW 1
39 0601802218 FUSE HOLDER, 3P 1
39A 0601806653 FUSE (RIGHT SIDE) 20A 1
39B 0601802149 FUSE ( CENTER) 10A 1
40 0027103020 MACHINE SCREW 2
41 0601815154 TERMINAL BLOCK 1
42 0027104016 MACHINE SCREW 2
43 3871824004 CONTROL PANEL STOPPER 1
44 0041206000 WASHER, FLAT 1
45 0605010502 SNAP PIN 1
46 M4213500104 CONTROL BOX COVER 1
47 0016908020 HEX HEAD BOLT 8
48 M4213400104 CONTROL BOX BACK PANEL 1
49 0016908020 HEX HEAD BOLT 8
50 0226900300 EDGING 1
51 0226900215 EDGING 1
52 0017110040 HEX HEAD BOLT 3
52A 0207010000 HEX NUT 3
53 0016908020 HEX HEAD BOLT 8
54 0016908020 HEX HEAD BOLT 7
PAGE 82 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 83
1
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 M4923200034 ENGINE, JOHN DEERE 6068HF485 1
1-1 0602041292 OIL FILTER CARTRIDGE, OIL FILTER ........... 1 ......... RE504836
1-2 0602042596 PRIMARY FUEL FILTER CARTRIDGE ............ 1 ......... RE529643
1-3 0602042597 FINAL FUEL FILTER CARTRIDGE .................. 1 ......... RE522878
2 0602060015 BLOWER FAN .................................................. 1 ......... 4735-42599-02
3 0602061003 FAN SPACER ................................................... 1 ......... R81876
4 0012110110 HEX HEAD BOLT 4
5 0042510000 WASHER, LOCK 4
6 M3303200404 ENGINE FOOT 2
7 0010312030 HEX HEAD BOLT 6
8 0042512000 WASHER, LOCK 4
9 0605000011 RUBBER SUSPENSION 2
10 0030016000 HEX NUT 4
11 0040016000 WASHER, LOCK 4
12 M4923200014 RADIATOR 1
12A M4493601304 ACOUSTIC SHEET 2
13 0602011062 CAP 1
14 M9200101004 ADAPTOR 1
15 0150000016 O-RING 1
16 M4310201103 SUPPORT, RADIATOR 1
17 M4310201203 SUPPORT, RADIATOR 1
17A M4493601504 ACOUSTIC SHEET 1
18 0016908020 HEX HEAD BOLT 16
19 M4310600304 RUBBER SHEET 2
20 0010112060 HEX HEAD BOLT 4
21 0030012000 HEX NUT 8
22 0041212000 WASHER, FLAT 8
23 M4310200904 BRACKET, RADIATOR 2
24 0016910025 HEX HEAD BOLT 4
25 0016910025 HEX HEAD BOLT 2
26 M4923200044 INTER COOLER 1
27 M4310201304 BRACKET, INTER COOLER 1
27A M4493601604 ACOUSTIC SHEET 1
28 M4310201404 BRACKET, INTER COOLER 1
28A M4493601604 ACOUSTIC SHEET 1
29 0010110040 HEX HEAD BOLT 4
29A 0030010000 HEX NUT 4
29B 0040010000 WASHER, LOCK 4
29C 0041210000 WASHER, FLAT 8
30 0016910025 HEX HEAD BOLT 4
31 M4310301103 FAN SHROUD 1
PAGE 84 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 85
1
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY.REMARKS
32 M4310301203 FAN SHROUD 1
M4493601204 ACOUSTIC SHEET 1
33 0016908020 HEX HEAD BOLT 6
34 0016908020 HEX HEAD BOLT 4
35 M4310300903 FAN GUARD 1
36 M4310301003 FAN GUARD 1
37 0016908020 HEX HEAD BOLT 11
38 M4310300403 FAN GUARD 1
39 0016908020 HEX HEAD BOLT 8
40 M4310500803 RADIATOR HOSE, UPPER 1
41 M4310500903 RADIATOR HOSE, LOWER 1
42 0605515143 HOSE BAND 1
43 0605515142 HOSE BAND 3
44 M4310401004 INTER COOLER PIPE 1
45 M4310501303 INTER COOLER HOSE 1
46 M4310501003 INTER COOLER HOSE 1
47 M4310501403 INTER COOLER HOSE 1
48 0605515207 HOSE BAND 1
49 0605515208 HOSE BAND 3
50 0605515209 HOSE BAND 3
51 M4310600404 BRACKET, INTER COOLER PIPE 1
52 0016908020 HEX HEAD BOLT 2
53 0602326063 U BOLT 1
54 0602046538 AIR CLEANER 1
54A 0602046617 OUTER ELEMENT, AIR CLEANER ................ 1 ........... P812363
54B 0602046618 INNER ELEMENT, AIR CLEANER .................. 1 ........... P838813
55 0602040690 INDICATOR, AIR CLEANER 1
56 0602040559 BAND, AIR CLEANER 2
57 0016908020 HEX HEAD BOLT 4
58 0207008000 HEX NUT 4
59 M4373200304 BRACKET, AIR CLEANER 1
60 0016908020 HEX HEAD BOLT 4
61 M4383000104 PIPE, AIR CLEANER 1
62 0602040365 90 DEGREE ELBOW 1
63 0605515260 HOSE BAND 3
64 0602022580 ADAPTER 1
65 0602022561 90 DEGREE ELBOW 1
66 0603306590 CONNECTOR 1
67 0603300285 ROCKNUT 1
68 0605511395 VALVE 1
69 0603306395 HOSE JOINT 1
PAGE 86 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
ENGINE AND RADIATOR ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 87
1
ENGINE AND RADIATOR ASSY.
NO. PART NO. PART NAME QTY.REMARKS
70 0602021070 CAP 1
71 0269200660 DRAIN HOSE 1
72 0802081003 RESERVE TANK 1
73 0602010900 RESERVE TANK CAP 1
74 M4316100103 RESERVE TANK BRACKET 1
75 0016910025 HEX HEAD BOLT 2
76 0199901500 HOSE 1
77 0193601600 HOSE 1
78 0193600700 HOSE 1
79 0605515106 HOSE BAND 3
80 0191601700 BLOWBY HOSE 1
82 M4483600003 HOSE GUIDE 1
83 0016908020 HEX HEAD BOLT 2
84 0602017090 DRAIN VALVE 1
85 0602042601 LEAK OFF LINE 1
86 0017110020 HEX HEAD BOLT 1
86A 0040510000 TOOTHED WASHER 1
87 0602220911 CLAMP 1
88 0602220910 CLAMP 1
89 0602202452 ENGINE WIRE HARNESS 1
90 0602015230 FAN BELT 1
91 813NLU0000T COOLANT LEVEL SWITCH ............................. 1.......... REPLACES P/N 0602123290
DCA-220SSJ/SSJU— ENGINE AND RADIATOR ASSY.
PAGE 88 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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. PART NO. PART NAME QTY.REMARKS
1 M4230700003 TERMINAL BOARD 1
2 M9220100304 OUTPUT TERMINAL BOLT 8
3 0801830804 TIE BOLT 8
4 0039316000 HEX. NUT 16
5 0040016000 SPRING WASHER 24
6 0041416000 PLAIN WASHER 32
7 3461860504 TERMINAL PLATE 3
8 0019208040 HEX. HEAD BOLT 5
9 M4236100403 TERMINAL COVER 1
10 M4236100504 OUTPUT WINDOW 1
11 0605010040 HINGE 2
12 0027103010 MACHINE SCREW 4
12A 0030003000 HEX NUT 4
12B 0041203000 WASHER, FLAT 4
13 0027103015 MACHINE SCREW 4
13A 0030003000 HEX NUT 4
14 M9220100804 SET SCREW 2
14A 0040006000 SPRING WASHER 2
14B 0042806000 PLAIN WASHER 2
14C 0080200005 RETAINING RING 2
15 0019206015 HEX HEAD BOLT 4
16 M4236400004 OUTLET CABLE COVER 1
17 M4236400104 OUTLET CABLE COVER SUPPORTER 1
18 0019206015 HEX HEAD BOLT 8
19 0601815194 TERMINAL BLOCK 1
20 0025304015 MACHINE SCREW 2
21 0601850275 GROMMET 1
22 0601851780 GROMMET 2
23 0601808803 CIRCUIT BREAKER, 1P 20A 2
24 0601808804 CIRCUIT BREAKER, 2P 50A 3
25 C3261600704 CIRCUIT BREAKER BRACKET 1
25-1 0222100150 RUBBER CUSHION 1
26 0019206020 HEX HEAD BOLT 2
27 0601812598 RECEPTACLE, GF-530EM 20A 2
28 0601812565 RECEPTACLE, CS6369 50A 3
29 0025304015 MACHINE SCREW 10
29A 0207004000 HEX NUT 10
30 M4236400204 COVER 1
31 0019206015 HEX HEAD BOLT 8
32 M4236100303 TERMINAL COVER 1
33 0010112045 HEX HEAD BOLT 2
34 0041212000 PLAIN WASHER 2
35 0805009804 STAY RUBBER 2
36 0030012000 HEX NUT 2
37 0605011505 STAY 1
38 0025305015 HEX HEAD BOLT 4
39 M4236100604 COVER 1
40 M4236400304 BRACKET 1
41 0019206015 HEX HEAD BOLT 2
PAGE 90 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— BATTERY ASSY.
BATTERY ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 91
1
DCA-220SSJ/SSJU— BATTERY ASSY.
BATTERY ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 0168614551 BATTERY, 145G51 1
2 C9109100604 BATTERY SHEET 1
3 0805000904 BATTERY BAND 1
4 0805002904 BATTERY BOLT 2
5 0037808000 WING NUT 2
6 0040008000 SPRING WASHER 2
7 0041608000 PLAIN WASHER 2
8 C1346600004 BATTERY CABLE 1
9 C1346600104 BATTERY CABLE 1
10 EARTH CABLE ......................................................... 1 .............. MAKE LOCALLY
11 0347010003 HEX HEAD BOLT 2
12 0208110000 HEX NUT 2
13 0845040414 TERMINAL CAP (+) 1
14 0845041304 TERMINAL CAP (-) 1
15 0017116030 HEX HEAD BOLT 1
16 0040516000 TOOTHED WASHER 1
17 0040520000 TOOTHED WASHER 1
PAGE 92 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — 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. PART NO. PART NAME QTY.REMARKS
1 M4330100602 MUFFLER 1
2 0016910025 HEX. HEAD BOLT 4
3 M4333000303 EXHAUST PIPE 1
4 0602325066 CLAMP 1
5 M4333200004 GASKET 1
6 0010112055 HEX. HEAD BOLT 4
6A 0040012000 SPRING WASHER 4
6B 0041212000 PLAIN WASHER 4
7 M4330300004 COVER 2
8 0016908020 HEX. HEAD BOLT 4
9 M4333300304 BRACKET 1
10 0016908020 HEX. HEAD BOLT 4
11 0602326062 U-BOLT SET 1
PAGE 94 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— FUEL TANK ASSY.
FUEL TANK ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 95
1
DCA-220SSJ/SSJU— FUEL TANK ASSY.
FUEL TANK ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 C1363001403 FUEL TANK 1
1-1 0845500104 CAP, FUEL TANK 1
1-2 0810105400 FUEL FILTER 1
2 0605501092 FUEL GAUGE SENDER 1
2A 0605516090 GASKET 1
3 0022905015 MACHINE SCREW 5
4 M4363200104 TANK BAND 2
5 0805003414 SUPPORTER SHEET 4
6 0016908020 HEX HEAD BOLT 2
7 0207308000 HEX NUT 2
8 0222100120 RUBBER SHEET 2
9 0222100180 RUBBER SHEET 2
10 0130206000 STREET ELBOW, 1/2” 1
11 8085512104 LONG NIPPLE 1
12 0603325011 VALVE,1/2” 1
13 0132006000 PLUG, 1/2” 1
14 0191302200 SUCTION HOSE 1
15 0191302800 RETURN HOSE 1
16 0605515109 HOSE BAND 4
PAGE 96 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENCLOSURE ASSY.
ENCLOSURE ASSY.
THE SERIAL NUMBER MAY BE REQUIRED.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 97
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DCA-220SSJ/SSJU— ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 C1413004402 BASE 1
2 M1413400404 COVER 1
3 0019208020 HEX. HEAD BOLT 4
4 M4423000302 FRONT FRAME 1
4A M4493102503 ACOUSTIC SHEET 1
5 M4423000402 FRONT FRAME 1
5A M4493102503 ACOUSTIC SHEET 1
6 0016908020 HEX. HEAD BOLT 10
7 0019210035 HEX. HEAD BOLT 8
8 M4423200304 COVER, FRONT FRAME 1
8A M4493102704 ACOUSTIC SHEET 1
9 0019208020 HEX. HEAD BOLT 6
10 M4423200403 OVER COVER, FRONT FRAME 1
11 0019208020 HEX. HEAD BOLT 14
12 M4423300004 DISCHARGE GUIDE 1
12A M4493601404 ACUSTIC SHEET 1
13 M4423300104 DISCHARGE GUIDE 1
13A M4493601404 ACOUSTIC SHEET 1
14 0019206020 HEX. HEAD BOLT 12
15 M4423200204 FRONT FRAME COVER 1
15A M4493102604 ACOUSTIC SHEET 1
16 0019208020 HEX. HEAD BOLT 10
17 M4433000102 CENTER FRAME 1
17A M4493200104 ACOUSTIC SHEET 1
18 0010114050 HEX HEAD BOLT 4
18A 0030014000 HEX NUT 4
18B 0040014000 SPRING WASHER 4
18C 0041214000 PLAIN WASHER 8
19 0010120045 HEX HEAD BOLT 4
19A 0030020000 HEX NUT 4
19B 0040020000 SPRING WASHER 4
19C 0041220000 PLAIN WASHER 8
20 M4443000102 REAR FRAME 1
20A M4493301904 ACOUSTIC SHEET 1
21 0019210035 HEX HEAD BOLT 4
22 M4443300204 COVER, REAR FRAME 1
22A M4493302004 ACOUSTIC SHEET 1
PAGE 98 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
THE SERIAL NUMBER MAY BE REQUIRED.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
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. PART NO. PART NAME QTY.REMARKS
24 0207306000 HEX. NUT 11
25 0019208020 HEX. HEAD BOLT 10
26 M4443200403 DOOR, REAR FRAME 1
27 M4443600004 WINDOW PLATE 1
28 0207306000 HEX. NUT 8
28A 0041206000 PLAIN WASHER 8
29 B9114000002 DOOR HANDLE 1
30 0021806016 MACHINE SCREW 4
30A 0030006000 HEX. NUT 4
31 0845047104 HINGE 2
31A 0845045004 WASHER 2
32 0019208020 HEX. HEAD BOLT 3
33 0845031504 BLIND PLUG 2
34 0600800320 MANUAL PAK 1
35 0027106016 MACHINE SCREW 4
36 M4463100202 ROOF PANEL 1
36A M4493501003 ACOUSTIC SHEET 1
37 M3310600004 COVER 1
38 0019208020 HEX HEAD BOLT 4
39 M4463200202 ROOF PANEL 1
39A M4493501903 ACOUSTIC SHEET 1
40 M4463200403 REAR ROOF DUCT 1
40A M4493502004 ACOUSTIC SHEET 1
41 0016908020 HEX HEAD BOLT 10
42 M4463400003 DUCT COVER 1
43 0016908020 HEX HEAD BOLT 7
44 M4463200304 COVER 2
45 0016906020 HEX HEAD BOLT 12
46 M4465300204 GUTTER 2
47 0019206016 HEX HEAD BOLT 8
48 0019208020 HEX. HEAD BOLT 32
49 M4453200102 SPLASHER PANEL 1
49A M4493404604 ACOUSTICSHEET 1
50 0019108065 HEX. HEAD BOLT 6
50A 0042308000 SPRING WASHER 6
50B 0042408000 PLAIN WASHER 6
PAGE 100 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— ENCLOSURE ASSY. (CONT.)
ENCLOSURE ASSY. (CONT.)
THE SERIAL NUMBER MAY BE REQUIRED.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE 5-BLACK
2-WHITE 6-CATERPILLAR YELLOW
3-SPECTRUM GREY 7-CATO GOLD
4-SUNBELT GREEN 8-RED
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. PART NO. PART NAME QTY.REMARKS
51 M4453001203 SIDE DOOR 1
51A M4493403804 ACOUSTIC SHEET 1
52 M4453001303 SIDE DOOR 1
52A M4493403904 ACOUSTIC SHEET 1
53 M4453001003 SIDE DOOR 1
53A M4493403004 ACOUSTIC SHEET 1
54 M4453001103 SIDE DOOR 1
54A M4493403104 ACOUSTIC SHEET 1
55 M4453301004 DUCT 2
55A M4493404004 ACOUSTIC SHEET 2
56 M4453300504 DUCT 1
56A M4493403204 ACOUSTIC SHEET 1
57 M4453300704 DUCT 1
57A M4493403404 ACOUSTIC SHEET 1
58 M4453300804 DUCT 1
58A M4493403504 ACOUSTIC SHEET 1
59 0207008000 HEX. NUT 35
60 B9114000002 DOOR HANDLE 4
61 0825007362 DOOR HANDLE 3
62 0021806016 MACHINE SCREW 28
62A 0030006000 HEX. NUT 28
63 M4453600004 GUTTER 3
64 M4453600104 GUTTER 2
65 0019206016 HEX. HEAD BOLT 15
66 0845046904 HINGE 6
66A 0845045004 WASHER 6
67 0845047004 HINGE 5
67A 0845045004 WASHER 5
68 0019208020 HEX. HEAD BOLT 25
69 0601850097 STOPPER 9
70 0025408025 MACHINE SCREW 9
71 0845031504 BLIND PLUG 11
PAGE 102 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 103
1
DCA-220SSJ/SSJU— RUBBER SEALS ASSY.
RUBBER SEALS ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1 0229201240 SEAL RUBBER 4
2 0228900945 SEAL RUBBER 4
3 0228901200 SEAL RUBBER 3
4 0228901260 SEAL RUBBER 3
5 0228901055 SEAL RUBBER 4
6 0228900600 SEAL RUBBER 1
7 0228900660 SEAL RUBBER 1
8 0229201060 SEAL RUBBER 1
9 0229200660 SEAL RUBBER 2
10 0228801050 SEAL RUBBER 2
11 0228800595 SEAL RUBBER 1
12 0228800635 SEAL RUBBER 1
13 0228100560 SEAL RUBBER 2
14 0228100370 SEAL RUBBER 2
15 0229201020 SEAL RUBBER 2
16 0228301200 SEAL RUBBER 2
PAGE 104 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
DCA-220SSJ/SSJU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 105
1
DCA-220SSJ/SSJU— NAMEPLATE AND DECALS ASSY.
NAMEPLATE AND DECALS ASSY.
NO. PART NO. PART NAME QTY.REMARKS
1-1 M4550000303 DECAL; OPERATING PROCEDURES ........................ 1 ........... M45000030
1-2 B9521100404 DECAL; SAFETY INSTRUCTIONS ............................. 1 ........... B92110040
1-3 C9521100003 DECAL; CAUTION ....................................................... 2 ........... C92110000
CONTROL PANEL & BOX GROUP
2-1 C1550000102 DECAL; CONTROL PANEL .......................................... 1 ........... C15000010
2-2 0800520904 PLATE; AMMETER CHANGE- OVER SWITCH ........... 1 ........... N-2438
2-3 0800520814 PLATE; VOLTMETER CHANGE- OVER SWITCH ........ 1 ........... N-2439
2-4 B9531100604 DECAL; WARNING ELECTRIC SHOCK HAZARD ....... 2 ........... B93110060
2-5 M9520200404 DECAL; OVER CURRENT RELAY .............................. 1 ........... M92020040
2-6 C0551000903 DECAL; SETTING FOR OUTPUT VOLTAGE ............... 1 ........... C05100090
2-7 M9522000504 DECAL; CIRCUIT BREAKER ...................................... 1 ........... M92200050
2-8 C9521007504 DECAL; DIAGNOSTIC SWITCH .................................. 1 ........... C92100750
ENGINE & RADIATOR GROUP
3-1 6360620204 DECAL; OIL DRAIN PLUG .......................................... 1 ........... S1885
3-2 6360610304 DECAL; WATER ........................................................... 1 ........... S1880
3-3 B9504000404 DECAL; WARNING MOVING PARTS ........................... 2 ........... B90400040
3-4 1320610603 DECAL; WATER - OIL CHECK ..................................... 1 ........... S1760
3-5 B9504100104 DECAL; WARNING HOT COOLANT ............................ 1 ........... B90410010
3-6 B9504000304 DECAL; CAUTION HOT PARTS ................................... 1 ........... B90400030
OUTPUT TERMINAL GROUP
4-1 M1550000703 DECAL; RECEPTACLE & CIRCUIT BREAKER ........... 1 ........... M15000070
4-2 0840614104 DECAL; GROUND ........................................................ 1 ........... S2635
4-3 9039209064 DECAL; START CONTACT .......................................... 1 ........... S4468
4-4 M9520000704 DECAL; 3- PHASE OUTPUT TERMINAL .................... 1 ........... M92000070
4-5 0840619904 DECAL; DANGER HIGH VOLTAGE .............................. 1 ........... S2731
4-6 M9520100503 DECAL; WARNING ...................................................... 1 ........... M92010050
BATTERY GROUP
5-1 0800689504 DECAL; - ...................................................................... 1 ........... S2091
5-2 0800689404 DECAL; + ..................................................................... 1 ........... S2090
5-3 C9505300004 DECAL; CAUTION ....................................................... 1 ........... C90530000
MUFFLER GROUP
6-1 B9504200004 DECAL; WARNING ENGINE EXHAUST ...................... 1 ........... B90420000
FUEL TANK GROUP
7-1 1320620904 DECAL; DIESEL FUEL ................................................ 1 ........... S1756
7-2 6360620004 DECAL; FUEL DRAIN PLUG ....................................... 1 ........... S1883
BONNET GROUP
8-1 0840625902 DECAL; MQ ................................................................. 1 ........... S3057
8-2 0600500090 EMBLEM 2
0021106016 MACHINE SCREW 4
8-3 C1560100303 STRIPE 1
8-4 C0560100403 STRIPE 1
8-5 C1560100204 STRIPE 2
8-6 C1560100404 STRIPE 1
8-7 C1560100004 STRIPE 2
8-8 C1560100103 STRIPE 1
8-9 C0560100303 STRIPE 1
9 M9503200104 DECAL, DANGER EXHAUST. GAS (INDOOR) ............ 1 ........... A90400000
PAGE 106 — DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09)
Effective: February 22, 2006 TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and credit
will be allowed, subject to the following provi-
sions:
1. A Returned Material Authorization must
be approved by Multiquip prior to ship-
ment.
2. To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers, quanti-
ties, and descriptions of the items to be
returned.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
c. The list must state the reason(s) for
the return.
d. The list must reference the sales
order(s) or invoice(s) under which the
items were originally purchased.
e. The list must include the name and
phone number of the person request-
ing the RMA.
3. A copy of the Return Material Authoriza-
tion must accompany the return shipment.
4. Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5. Parts must be in new and resalable con-
dition, in the original Multiquip package (if
any), and with Multiquip part numbers
clearly marked.
6. The following items are not returnable:
a. Obsolete parts. (If an item is in the
price book and shows as being re-
placed by another item, it is obsolete.)
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were pur-
chased more than six months prior to
the return date.
c. Any line item with an extended dealer
net price of less than $5.00.
d. Special order items.
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
7. The sender will be notified of any material
received that is not acceptable.
8. Such material will be held for five working
days from notification, pending instruc-
tions. If a reply is not received within five
days, the material will be returned to the
sender at his expense.
9. Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a spe-
cific date and all orders received on or after that
date will be billed at the revised price. Rebates
for price declines and added charges for price
increases will not be made for stock on hand
at the time of any price change.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
A $35.00 surcharge will be added to the invoice
for special handling including bus shipments,
insured parcel post or in cases where Multiquip
must personally deliver the parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of the
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental dam-
ages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made
in connection with the sale of parts or trade
accessories nor as to any engine not manufac-
tured by Multiquip. Such warranties made in
connection with the sale of new, complete units
are made exclusively by a statement of war-
ranty packaged with such units, and Multiquip
neither assumes nor authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products. Apart from such written statement of
warranty, there are no warranties, express,
implied or statutory, which extend beyond the
description of the products on the face hereof.
DCA-220SSJ/SSJU— OPERATION AND PARTS MANUAL — REV. #1 (01/06/09) — PAGE 107
1
NOTE PAGE
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
Your Local Dealer is:
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER
ON-HAND
WHEN CALLING
© COPYRIGHT 2009, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other
trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical
data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications,
design or the information published in this publication at any time without notice and without incurring any obligations.
MQ Power
1800 Water Ridge Rd. Tel. (800) 883-2551
Suite 500/600 Fax (972) 315-1847
Lewisville, TX 75057
Contact: mqpower@multiquip.com
Web: www.mqpower.com
MQ Parts Department
800-427-1244 Fax: 800-672-7877
310-537-3700 Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
Manufactured for
Multiquip Inc.
by
DENYO CO., LTD, JAPAN
