MULTIQUIP DCA-220SSJU Operation And Parts Manual Download

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Revision #1 (03/22/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

WHISPERWATT

SERIES

MODEL DCA-220SSJ

60 Hz GENERATOR

PARTS LIST NO. C1870300404

Summary of Contents for DCA-220SSJU

Page 1: ...RTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 1 03 22 07 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 220SSJ 60 Hz GENERATOR PARTS LIST NO C1870300404 ...

Page 2: ...PAGE 2 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 ...

Page 3: ...DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 PAGE 3 1 NOTE PAGE ...

Page 4: ...ation 40 42 Load Application 43 Generator Outputs 44 GaugeReading 45 OutputTerminal 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 JacketWater Heater Battery Charger 59 Maintenance Trailer 60 63 TrailerWiring Diagram 64 GeneratorWiring Diagram 65 EngineWiring Dia...

Page 5: ...b parts order system or by fax qualify for the following extra discounts Ordered Standard Stock orders via orders 750 list and above Fax 3 10 Web 5 10 Special freight allowances when you order 10 or more line items via Web or Fax FedEx Ground Service at no charge for freight No other allowances on freight shipped by any other carrier Common nuts bolts and washers all items under 1 00 list price do...

Page 6: ... K 4 2 W K 8 4 t h g i e W y r D g k 0 3 1 3 s b l 5 9 8 6 t h g i e W t e W g k 0 2 5 3 s b l 3 5 7 7 s n o i t a c i f i c e p S e n i g n E 2 e l b a T l e d o M 5 8 4 F H 8 6 0 6 E R E E D N H O J e p y T r i a r i a d e g r a h c o b r u t n o i t c e j n i t c e r i d d e l o o c r e t a w e l c y c 4 s r e d n i l y C f o o N s r e d n i l y c 6 e k o r t S x e r o B m m 7 2 1 x m m 6 0 1 n...

Page 7: ...E M I D 3 E L B A T e c n e r e f e R r e t t e L m m t f n o i s n e m i D r e t t e L e c n e r e f e R m m t f n o i s n e m i D A m m 0 4 9 n i 0 0 7 3 F m m 0 0 5 3 n i 0 8 7 3 1 B m m 0 4 9 n i 0 0 7 3 G m m 0 0 7 1 n i 2 9 6 6 C m m 0 5 0 1 n i 3 3 1 4 H m m 0 4 2 1 n i 1 8 8 4 D m m 0 5 0 1 n i 3 3 1 4 E m m 0 5 0 1 n i 3 3 1 4 ...

Page 8: ... 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 amp...

Page 9: ...environment Thisgenerator otherproperty 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 HAZ...

Page 10: ...touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator HighTemperatures Allowtheengine 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 fr...

Page 11: ...quipment it is important to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC providesguidelinesforpropergroundingandspecifies 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 ground...

Page 12: ...sh 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 i...

Page 13: ...s 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 i...

Page 14: ...ls 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 GENERATOR DECALS Figure 2 Generator Decals ...

Page 15: ...DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 PAGE 15 1 DCA 220SSJ GENERATOR DECALS Figure 3 Generator Decals Cont inued ...

Page 16: ...PAGE 16 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 Figure 4 Typical Generator Grounding Application DCA 220SSJ INSTALLATION ...

Page 17: ...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 aminimumof8ft intotheground When connecting the generator to any building...

Page 18: ...ta 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 is powered by a 6 cylinder water cooled direct injection turbocharged John Deere 6068HF485Turbo Diesel Engine This engine is designed to meet every performance requirement fo...

Page 19: ...i m r e T t u p t u O 2 y l b m e s s A s e l c a t p e c e R t u p t u O 3 y l b m e s s A r e t l i F r i A 4 y l b m e s s A r e l f f u M 5 y l b m e s s A k n a T l e u F 6 y l b m e s s A e n i g n E 7 y l b m e s s A y r e t t a B 8 y l b m e s s A r o t a r e n e G 9 y l b m e s s A r e k a e r B t i u c r i C 0 1 y l b m e s s A y a l p s i D c i t s o n g a i D 1 1 y l b m e s s A l e n ...

Page 20: ...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 thescreeneithermovingtheparameterselectiontoward the left or upward Figure 6 Diagnostic Display Panel 3 RightArrowButton Pressthisbuttontoscrollthrough thescreeneithermovingtheparameterselectiontoward the right or down...

Page 21: ...splayed Touchingthe ArrowButtons willscrollthrough 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 DISP...

Page 22: ...IL 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...

Page 23: ...splayed Touchingthe ArrowButtons willscrollthrough 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 DISP...

Page 24: ...IL 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...

Page 25: ... via a daisy chained RS 485 port If at any time during system initialization or normal operation an auxiliary gage should fail the single orfourparameterscreenwillbereplacedwiththe MLink Gage Fault message 3 To acknowledge and Hide the fault and return to the singleorfourparameterdisplay touchthe EnterButton 4 The display will return to the single or four parameter screen GO TO 1 UP DISPLAY STORED...

Page 26: ...M OIL PRES 98 14 2 57 PSI 1000 RPM LOAD RPM BATT VOLT ENG RPM OIL PRES SPN110 FMI10 HIGH COOLANT TEMP WARNING 1 of x MORE HIDE SPN110 FMI10 HIGH COOLANT TEMP 1 of x MORE HIDE 4 To acknowledge and Hide the fault and return to the singleorfourparameterdisplaytouchthe EnterButton 5 The display will return to the single or four parameter display but the display will contain the Active Fault warning ic...

Page 27: ...COOL 1800 RPM 0 1500 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 faultandreturnthescreentothesingleorfourparameter 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 HI...

Page 28: ...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 G ENGINE 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 ...

Page 29: ...play touch the Menu Button COOL 1800 RPM 0 1500 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 METRI...

Page 30: ...utton 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 t...

Page 31: ...can function on 17 Touchingthe EnterButton againtogglesthe Automatic Scan function off 18 Oncethe UseDefaults CustomSetup 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 EN...

Page 32: ...SPLAY 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 me...

Page 33: ...E 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...

Page 34: ...e 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 displ...

Page 35: ...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 0 1500 3000 TEMP ENG RPM 98 ...

Page 36: ...e is not supported DATAERROR Diagnostic Display has received an error message from the ECU for the displayed message EMPTY No parameter selected for this 4 UP quadrant WAITTO 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 N...

Page 37: ...ltmeter 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 andWOutput Terminal Lugs from overload Located behind the generator control panel is the Generator Control Box This box contains some of the ...

Page 38: ...een 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 thisgaugebeshouldreadbetween180 and230 F 82 C and110 C 5 Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides c...

Page 39: ...ure 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 ...

Page 40: ...00V GFCI receptacles 20 amp Two 2 GFCI Circuit Breakers 20 amps Five 5 Output Terminal Lugs U V W O Ground OutputTerminal Panel TheOutputTerminalPanel Figure9 shownbelowislocated ontheright handside leftfromcontrolpanel ofthegenerator Lift up on the cover to gain access to receptacles and terminal lugs NOTE Terminal legs O and Ground areconsideredbondedgrounds Figure 9 Output Terminal Panel DCA 22...

Page 41: ...t current on all three receptacles is dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 12 on the control panel to obtain the desired voltage Turning the knob clockwise will increasethe voltage turning the knob counter clockwise will decrease the voltage Figure 11 240 139VTwist Lock Auxiliary Receptacles DCA 220SSJ OUTPUT TERMINAL PANEL FA...

Page 42: ...d 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 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 ...

Page 43: ... 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 generato...

Page 44: ...N CHANGINGVOLTAGES 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 e l b a l i a v A s e g a t l o V 7 e l b a T e s a h P e e r h T e l b a t c e l e S V 8 0 2 V 0 2 2 V 0 4 2 V 6 1 4 V ...

Page 45: ...re 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 ACVoltmeter Change Over Switch Figure 18 ACVoltmeter Gauge Volt reading onW 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 connec...

Page 46: ...1 Jumperthevoltagechange overboardfor240Voperation as shown in Figure 21 Figure 22 UVWO Terminal Lugs 3Ø 240V 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 voltag...

Page 47: ...n Figure 27 UVWO Terminal Lugs 3Ø 480V Connections 1Ø 480V UVWOTerminal OutputVoltages 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 1Ø 277V UVWOTerminal OutputVoltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 26 2 Connect the load...

Page 48: ...he 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 FuelTank System Refilling the Fuel System Fuel Check Th...

Page 49: ...k Figure 34 Figure 34 Full Fuel Tank Figure 35 Fuel Expansion 3 Open cabinet doors on the right side of the generator fromgeneratorcontrolpanelposition Removefuelcap 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 REFUELINGTHE GENERATOR Die...

Page 50: ...ing 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 PRE SETUP Whentheantifreezeismixedwith water the antifreeze mixing ratio must be less than 50 NOTE If adding coo...

Page 51: ... 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 electricaldamagetothe 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 batter...

Page 52: ...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 starti...

Page 53: ...ion 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 ...

Page 54: ...ds 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 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 n...

Page 55: ...m any maintenance when the generator is in the auto mode WARNING AUTO MODE MAINTENANCE DCA 220SSJ GENERATORSTART UPPROCEDURE AUTOMODE WhentheMPECControlSwitch 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 ...

Page 56: ...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 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...

Page 57: ...ice After changing the air element press the dust indicator button to reset the indicator E C N A N E T N I A M N O I T C E P S N I 4 1 E L B A T s r H 0 1 Y L I A D s r H 0 5 2 s r H 0 0 5 s r H 0 0 0 1 E N I G N E s l e v e L d i u l F e n i g n E k c e h C X r e n a e l C r i A k c e h C X l e v e L d i c A y r e t t a B k c e h C X n o i t i d n o C t l e B n a F k c e h C X s k a e L r o f k ...

Page 58: ...ter 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 This unit is equipped with an automatic air bleeding system Check Oil Level Check the crankcase oil level prior to each use or when the fuel tank is filled I...

Page 59: ...ptacles will ONLY function when commercial power has been supplied to them Figure 59 To apply commercial power to these receptacles a power cord of adequate size will be required SeeTable 6 When using the generator in hot climates there is no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the jacket wat...

Page 60: ...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 peri...

Page 61: ...surgebrakingrequirestheinstallationofanactuator 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 ...

Page 62: ...d loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 17 Figure 61 Major Suspension Components DCA 220SSJ 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 rimiscracked theairpressureintheinner tube may cause pieces of the rim to explode break of...

Page 63: ...f 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 s t n e m e r i u q e R e u q r o T e r i T 8 1 e l b a T e z i S l e e h W s s ...

Page 64: ...PAGE 64 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ TRAILERWIRING DIAGRAM Figure 63 Trailer Towing Vehicle Wiring Diagram ...

Page 65: ...DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 PAGE 65 1 DCA 220SSJ GENERATORWIRING DIAGRAM Figure 64 GeneratorWiring Diagram ...

Page 66: ...PAGE 66 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ ENGINEWIRING DIAGRAM Figure 65 Engine Wiring Diagram ...

Page 67: ... a t o R e v i t c e f e D e c a l p e r d n a k c e h C d l e i F r e t i c x E e v i t c e f e D 1 N C n o K J s s o r c a s m h o 3 7 1 r o f k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g n e s I h g i H o t r e v e l e l t t o r h t e n i g n e n r u T e s o o l s n o i t c e n n o c g n i r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r...

Page 68: ... h g i H n o s i t h g i l t c e r r o c n i n o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r o t a i d a r r i a p e r n a e l C n e p o s r o o D s r o o d e s o l C g n i k a e l t s u a h x E t r a p y t l u a f r o s t e k s a g r i a p e r e c a l p e R d e d a o l r e v o g n i e b r...

Page 69: ...DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 PAGE 69 1 NOTE PAGE ...

Page 70: ... 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 Thefollowingsectionexplainsthedifferentsymbolsandremarks used in the Parts section of this manual Use the help numbers foundont...

Page 71: ...IATOR 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 06020466...

Page 72: ...PAGE 72 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ GENERATOR ASSY GENERATOR ASSY ...

Page 73: ...HEX HEAD BOLT 8 1 10 0042616000 SPRINGWASHER 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 SPRINGWSHER 8 5 0012112040 HEX HEAD BOLT 8 6 0042512000 SPRINGWASHER 8 7 C1130100103 STATOR ASSEMBLY 1 INCLUDES ITEMS W 7 1 0226100420 RUBBER SEAL 1 7 2 8171323004 CLAMPER...

Page 74: ...PAGE 74 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 GENERATOR ASSY DCA 220SSJ GENERATOR ASSY CONT ...

Page 75: ...ASKET BEARING 1 14 0010106060 HEX HEAD BOLT 4 14A 0040006000 SPRINGWASHER 4 14B 0041206000 PLAINWASHER 4 15 C1154400103 SUCTION COVER 1 16 0017106016 HEX HEAD BOLT 8 17 0343205150 HEX HEAD BOLT 12 18 0043605000 SPRINGWASHER 12 19 C1132300114 COVER FAN 1 20 0010106030 HEX HEAD BOLT 1 20A 0041206000 PLAINWASHER 1 20B 0600815000 NUT 1 21 0605000012 RUBBER SUSPENSION 2 22 0030020000 HEX NUT 4 22A 0040...

Page 76: ...PAGE 76 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ CONTROL PANEL ASSY CONTROL PANEL ASSY ...

Page 77: ...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 WATERTEMPERATURE GAUGE 1 20 0602123263 WATERTEMPERATURE UNIT 1 21 0602121081 CHARGING AMMETER 1 22 0602125090 FUEL ...

Page 78: ...PAGE 78 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 79: ...016 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 PART...

Page 80: ...PAGE 80 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 CONTROL BOX ASSY CONT DCA 220SSJ CONTROL BOX ASSY CONT ...

Page 81: ... 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 02...

Page 82: ...PAGE 82 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 83: ... 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 ...

Page 84: ...PAGE 84 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 85: ... 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 A...

Page 86: ...PAGE 86 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY ...

Page 87: ...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 TOOTHEDWASHER 1 87 0602220911 CLAMP 1 88 0602220910 CLAMP 1 89 0602202452 ENGINE WIRE HARNESS 1 90 0602015230 FAN BELT 1...

Page 88: ...PAGE 88 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY ...

Page 89: ...TAINING 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...

Page 90: ...PAGE 90 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ BATTERY ASSY BATTERY ASSY ...

Page 91: ...TERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 SPRINGWASHER 2 7 0041608000 PLAINWASHER 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 TOOTHEDWASHER 1 17 0040520000 TOOTH...

Page 92: ...PAGE 92 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ MUFFLER ASSY MUFFLER ASSY ...

Page 93: ...330100602 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 SPRINGWASHER 4 6B 0041212000 PLAINWASHER 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: ...PAGE 94 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ FUELTANK ASSY FUEL TANK ASSY ...

Page 95: ...2 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...

Page 96: ...0SSJ 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 ...

Page 97: ...08020 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 ...

Page 98: ...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 ...

Page 99: ...4 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...

Page 100: ...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 ...

Page 101: ...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 H...

Page 102: ...PAGE 102 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ RUBBER SEALS ASSY RUBBER SEALS ASSY ...

Page 103: ...UBBER 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: ...PAGE 104 DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 DCA 220SSJ NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY ...

Page 105: ...RNING 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 OUTPUTTERMINAL 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...

Page 106: ...s f Paint chemicals andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 Thesenderwillbenotifiedofanymaterial receivedthatisnotacceptable 8 Suchmaterialwillbeheldforfiveworking days from notification pending instruc tions Ifareplyisnotreceivedwithinfive days thematerialwillbereturnedtothe senderathisexpense 9 Creditonreturnedpartswillbeissuedat dealer net price at time of the original p...

Page 107: ...DCA 220SSJ OPERATION AND PARTS MANUAL REV 1 03 22 07 PAGE 107 1 NOTE PAGE ...

Page 108: ...N HERE S HOW TO GET HELP PLEASE HAVETHE MODEL AND SERIAL NUMBERON HANDWHENCALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower multiquip com Internet www mqpower com PARTS DEPARTMENT 800 427 1244 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 835 2551 FAX 310 638 8046 310 537 3700 TECHNICALASSISTANCE 800 835 2551 ...

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