MULTIQUIP Power WHISPERWATT DCA-220SSJ Leitfaden

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Revision #0 (02/04/14)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALLTIMES.

MODEL DCA220SSJ/SSJU

60HZ WHISPERWATT™ GENERATOR

(JOHN DEERE 6068HF485 DIESEL ENGINE)

PARTS LIST NO. C1870300404 (DCA220SSJ)

PARTS LIST NO. M4870300104B (DCA220SSJU)

PAGE 2 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)

Diesel engine exhaust and some of

DCA-220SSJ/SSJU — PROPOSITION 65 WARNING

DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14) — PAGE 3

DCA-220SSJ/SSJU — NOTE PAGE

PAGE 4 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)

DCA-220SSJ/SSJU — TABLE OF CONTENTS

MQ POWER DCA-220SSJ/SSJUMQ POWER DCA-220SSJ/SSJU

MQ POWER DCA-220SSJ/SSJU

WHISPERWHISPER

WHISPERWW

WAA

ATTTT

TTTT

TTTMTM

TMTM

GENERATORGENERATOR

GENERATOR

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Output Terminal Panel Connections ........................... 46-47

Setup ......................................................................... 48-51

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 .................................................. 72-75

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

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

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

Output Terminal Assembly ......................................... 88-91

Battery Assembly ...................................................... 92-93

Muffler Assembly ...................................................... 94-95

Fuel Tank Assembly .................................................. 96-97

Enclosure Assembly ............................................... 98-105

Rubber Seals Assembly ........................................ 106-107

Nameplate and Decals .......................................... 108-111

Terms and Condition of Sale — Parts .......................... 112

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

Specification and part number are subject to

change without notice.

NOTICE

DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14) — PAGE 5

DCA-220SSJ/SSJU — PARTS ORDERING PROCEDURES

www.multiquip.com

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 c k

■Ground

■Next Day

■Second/Third Day

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

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

Best Deal!

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

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

PAGE 6 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)

DCA-220SSJ/SSJU — SPECIFICATIONS

Table 1. Generator Specifications

Model DCA-220SSJ/SSJU

Type Revolving field, self ventil

open protected type synchronou

Armature Connection Star with Neutral

Phase 3

Standby Output 242 KVA (194 KW)

Prime Output 220 KVA (176 KW)

Voltage 240, OR 480V

Frequency 60 Hz

Speed 1800 rpm

Power Factor 0.8

AUX. AC Power Single Phase, 60 Hz

Voltage 120V

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.)

Table 2. Engine Specifications

Model

JOHN DEERE 6068HF48

DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14) — PAGE 7

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

Figure 1. Dimensions

SNOISNEMID.3ELBAT

ecnerefeR

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. #0 (02/04/14)

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. #0 (02/04/14) — PAGE 9

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.

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

This generator, other property, or the surrounding

environment could be damaged if you do not follow

instructions.

NOTICE

PAGE 10 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)

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.

■

HighTemperatures – 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.

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