Multiquip Automobile Parts DCA220SSJ SSJU User Manual

PARTS AND OPERATION MANUAL  
OPERATION AND PARTS MANUAL  
®
MODEL DCA220SSJ/SSJU  
60HZ WHISPERWATT™ GENERATOR  
(JOHN DEERE 6068HF485 DIESEL ENGINE)  
PARTS LIST NO. C1870300404 (DCA220SSJ)  
PARTS LIST NO. M4870300104B (DCA220SSJU)  
Revision #0 (02/04/14)  
THIS MANUAL MUST ACCOMPANY  
THE EQUIPMENT AT ALLTIMES.  
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DCA-220SSJ/SSJU — PROPOSITION 65WARNING  
Diesel engine exhaust and some of  
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DCA-220SSJ/SSJU — NOTE PAGE  
DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14) — PAGE 3  
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DCA-220SSJ/SSJU TABLE OF CONTENTS  
MQ POWER DCA-220SSJ/SSJU  
COMPONENT DRAWINGS  
WHISPERWATTTM GENERATOR  
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  
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  
OutputTerminal Panel Familiarization ........................ 40-42  
Load Application ............................................................. 43  
Generator Outputs .......................................................... 44  
Gauge Reading ............................................................... 45  
OutputTerminal 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  
TrailerWiring Diagram ..................................................... 64  
GeneratorWiring Diagram ............................................... 65  
EngineWiring Diagram ................................................... 66  
GeneratorTroubleshooting .............................................. 67  
Engine ControllerTroubleshooting ................................... 68  
Explanation of Code in Remarks Column ....................... 70  
Suggested Spare Parts .................................................. 71  
Terms and Condition of Sale — Parts .......................... 112  
NOTICE  
Specification and part number are subject to  
change without notice.  
PAGE 4 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)  
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DCA-220SSJ/SSJU — PARTS ORDERING PROCEDURES  
Ordering parts has never been easier!  
Choose from three easy options:  
Effective:  
January 1st, 2006  
Best Deal!  
Order via Internet (Dealers Only):  
Order parts on-line using Multiquip’s SmartEquip website!  
If you have an MQ Account, to obtain a Username  
and Password, E-mail us at: parts@multiquip.  
com.  
View Parts Diagrams  
Order Parts  
Print Specification Information  
To obtain an MQ Account, contact your  
District Sales Manager for more information.  
Use the internet and qualify for a 5% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
Goto www.multiquip.com and click on  
to log in and save!  
Order Parts  
Note: Discounts Are Subject To Change  
Fax your order in and qualify for a 2% 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)  
Note: Discounts Are Subject To Change  
Domestic (US) Dealers Call:  
Order via Phone:  
1-800-427-1244  
Non-Dealer Customers:  
International Customers should contact  
their local Multiquip Representatives for  
Parts Ordering information.  
Contact your local Multiquip Dealer for  
parts or call 800-427-1244 for help in  
locating a dealer near you.  
When ordering parts, please supply:  
Dealer Account Number  
Specify Preferred Method of Shipment:  
Dealer Name and Address  
UPS/Fed Ex  
DHL  
Truck  
Priority One  
Ground  
Shipping Address (if different than billing address)  
Return Fax Number  
Next Day  
Second/Third Day  
Applicable Model Number  
Quantity, Part Number and Description of Each Part  
NOTICE  
All orders are treated as Standard Orders and will  
ship the same day if received prior to 3PM PST.  
WE ACCEPT ALL MAJOR CREDIT CARDS!  
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DCA-220SSJ/SSJU — SPECIFICATIONS  
Table 1. Generator Specifications  
Model  
Type  
DCA-220SSJ/SSJU  
Revolving field, self ventila  
open protected type synchronous  
Armature Connection  
Phase  
Star with Neutral  
3
Standby Output  
Prime Output  
Voltage  
242 KVA (194 KW)  
220 KVA (176 KW)  
240, OR 480V  
60 Hz  
Frequency  
Speed  
1800 rpm  
Power Factor  
AUX. AC Power  
Voltage  
0.8  
Single Phase, 60 Hz  
120V  
4.8 KW (2.4 KW X 2)  
6,895 lbs. (3,130 kg.)  
7,753 lbs. (3,520 kg.)  
Output  
Dry Weight  
Wet Weight  
Table 2. Engine Specifications  
JOHN DEERE 6068HF48  
Model  
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DCA-220SSJ/SSJU — DIMENSIONS (TOP, SIDE AND FRONT)  
TABLE 3. DIMENSIONS  
Reference  
Dimension ft. (mm.)  
Reference Letter  
Dimension ft. (mm.)  
Letter  
A
B
C
D
E
37.00 in. (940 mm.)  
37.00 in. (940 mm.)  
41.33 in. (1,050 mm.)  
41.33 in. (1,050 mm.)  
41.33 in. (1,050 mm.)  
F
G
H
137.80 in. (3,500 mm.)  
66.92 in. (1,700 mm.)  
48.81 in. (1,240 mm.)  
Figure 1. Dimensions  
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DCA-220SSJ/SSJU — SAFETY MESSAGE ALERT SYMBOLS  
FORYOUR SAFETY ANDTHE 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".  
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.  
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.  
WARNING - LETHAL EXHAUST GASES  
NOTE  
Gasoline engine exhaust gases contain  
poisonous carbon monoxide. This gas is  
colorless and odorless, and can cause  
DEATH if inhaled. NEVER operate this  
Before using this generator, ensure that the operating  
individual has read and understands all instructions in  
this manual.  
equipment in a confined area or enclosed structure that  
does not provide ample free flow air.  
WARNING - EXPLOSIVE FUEL  
SAFETY MESSAGE ALERT SYMBOLS  
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.  
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.  
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.  
DANGER  
You WILL be KILLED or SERIOUSLY injured if you  
do not follow directions.  
WARNING  
WARNING - BURN HAZARDS  
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.  
You COULD be KILLED or SERIOUSLY injured if  
you do not follow directions.  
CAUTION  
You CAN be injured if you do not follow directions  
DANGER - ELECTROCUTION HAZARDS  
During operation of this generator, there  
exists the possibility of electrocution,  
electrical shock or burn, which can cause  
severe bodily harm or even DEATH!  
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DCA-220SSJ/SSJU — SAFETY MESSAGE ALERT SYMBOLS  
WARNING - ROTATING PARTS  
CAUTION - RESPIRATORY HAZARDS  
NEVER operate equipment with covers,  
or guards removed. Keep fingers, hands,  
hair and clothing away from all moving  
parts to prevent injury.  
ALWAYS wear approved respiratory  
protection.  
CAUTION - ACCIDENTAL STARTING  
CAUTION - SIGHT AND HEARING HAZARDS  
ALWAYS place the MPEC control switch  
in the OFF/RESET position when the  
generator is not in use.  
ALWAYS wear approved eye and  
hearing protection.  
CAUTION - OVER-SPEED CONDITIONS  
CAUTION - EQUIPMENT DAMAGE MESSAGES  
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.  
Other important messages are provided throughout this  
manual to help prevent damage to your generator, other  
property, or the surrounding environment.  
NOTICE  
This generator, other property, or the surrounding  
environment could be damaged if you do not follow  
instructions.  
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DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION  
ALWAYS check the machine for loosened threads or bolts  
before starting.  
DANGER - READTHIS MANUAL!  
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.  
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.  
The following safety guidelines should always be used when  
operating the DCA-220SSJ/SSJU Whisperwatt™ AC  
Generator.  
HighTemperatures – Allow the engine  
to cool before performing service and  
maintenance functions. Contact with  
hot! components can cause serious  
burns.  
General Safety:  
DO NOT operate or service this  
equipment before reading this entire  
manual.  
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  
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  
carbon monoxide gas.  
DO NOT place hands or fingers inside generator engine  
compartment when engine is running.  
protective devices required by the job.  
NEVER run engine without air filter.Severe engine damage  
may occur.  
NEVER operate this equipment when not  
feeling well due to fatigue, illness or taking  
medicine.  
DO NOT leave the generator running in the manual mode  
unattended.  
NEVER operate this equipment under the influence or  
drugs or alcohol.  
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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DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION  
Generator Grounding  
DANGER - ELECTROCUTION HAZARDS  
To guard against electrical shock and possible damage to  
the equipment, it is important to provide a good EARTH  
ground.  
During operation of this generator, there  
exists the possibility of electrocution,  
electrical shock or burn, which can cause  
severe bodily harm or even DEATH!  
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.  
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  
The following safety recommendations should also be  
followed:  
terminals, insufficient tightening of the terminal connections  
WET  
HANDS  
may cause damage to the generator  
ALWAYS make sure generator is properly grounded.  
NEVER use gas piping as an electrical ground.  
and electrical shock.  
NEVER grab or touch a live power  
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.  
cord with wet hands.  
POWER  
CORD  
(POWER ON)  
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.  
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  
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  
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 water.  
NEVER stand in water while AC power from the generator  
is being transfer to a load.  
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DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION  
Maintenance Safety  
Battery Safety  
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:  
can cause severe injury or even death through physical  
contact with live circuits. Turn all circuit breakers OFF  
The battery contains acids that can  
cause injury to the eyes and skin. To  
avoid eye irritation, always wear safety  
glasses.  
before performing maintenance on the generator.  
NEVER lubricate components or attempt service on a  
running machine.  
Use well insulated gloves when picking up the battery.  
ALWAYS disconnect the NEGATIVE battery terminal  
before performing service on the generator.  
DANGER - EXPLOSION HAZARDS  
Follow all Battery Safety Guidelines listed in this manual  
when handleing or servicing the generator.  
The risk of an explosion exists when performing service  
on the battery.To avoid severe injury or DEATH:  
ALWAYS allow the machine a proper amount of time to  
cool before servicing.  
DO NOT drop the battery.There  
is the possibility of risk that the  
battery may explode.  
Keep the machinery in proper running condition.  
Fix damage to the machine immediately and always  
replace broken parts.  
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.  
ALWAYS service air cleaner frequently to prevent engine  
malfunction.  
WARNING - BURN HAZARDS  
ALWAYS keep the battery charged. If the battery is not  
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.  
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.  
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.  
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.  
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.  
PAGE 12 — DCA-220SSJ/SSJU — OPERATION AND PARTS MANUAL — REV. #0 (02/04/14)  
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DCA-220SSJ/SSJU — RULES FOR SAFE OPERATION  
Towing &Transporting Safety  
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.  
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.  
Place chock blocks underneath wheel to prevent rolling,  
while parked.  
The following list of safety precautions should be followed  
when towing your generator:  
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.  
CAUTION - FOLLOWTOWING REGULATIONS  
Check with your local county or state safety towing  
regulations, in addition to meeting Department of  
Transportation (DOT) SafetyTowing Regulations, before  
towing your generator.  
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.  
ALWAYS shutdown engine before transporting.  
Tighten both fuel tank caps securely.  
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.  
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.  
Place support blocks underneath the trailer’s bumper to  
prevent tipping, while parked.  
Make sure the hitch and coupling of the towing vehicle  
are rated equal to, or greater than the trailer "gross vehicle  
weight rating.”  
Avoid sharp turns to prevent rolling.  
DO NOT transport generator with fuel in tank.  
ALWAYS inspect the hitch and coupling for wear. NEVER  
tow a trailer with defective hitches, couplings, chains etc.  
Emergencies  
ALWAYS know the location of the  
nearest fire extinguisher.  
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 know the location of the  
nearest and first aid kit.  
ALWAYS make sure the trailer is equipped with a "Safety  
Chain".  
ALWAYS know the location of the  
nearest phone or keep a phone on  
the job site, in case of emergencies.  
ALWAYS attach trailer’s safety chains to towing vehicle  
properly.  
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.  
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.  
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