Multiquip MQPower Whisperwatt Series 60Hz Generator DCA-220S User Manual

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUALRevision #1 (03/22/07)THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.WHISPERWATTTM SERIESMOD

PAGE 10 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — RULES FOR SAFE OPERATIONThe following safety guidelines should al

PAGE 100 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENCLOSURE ASSY. (CONT.)ENCLOSURE ASSY. (CONT.)THE SERIAL NUMBER

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 1011DCA-220SSJ— ENCLOSURE ASSY. (CONT.)ENCLOSURE ASSY. (CONT.)NO. PART NO. PART N

PAGE 102 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— RUBBER SEALS ASSY.RUBBER SEALS ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 1031DCA-220SSJ— RUBBER SEALS ASSY.RUBBER SEALS ASSY.NO. PART NO. PART NAME QTY. RE

PAGE 104 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— NAMEPLATE AND DECALS ASSY.NAMEPLATE AND DECALS ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 1051DCA-220SSJ— NAMEPLATE AND DECALS ASSY.NAMEPLATE AND DECALS ASSY.NO. PART NO.

PAGE 106 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Effective: February 22, 2006TERMS AND CONDITIONS OF SALE — PARTSPAYMENT TERM

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 1071NOTE PAGE

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUALYour Local Dealer is:MQ POWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-5

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 111DCA-220SSJ — RULES FOR SAFE OPERATIONPOWERCORD(POWER ON)WETHANDSDuring operatio

PAGE 12 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — RULES FOR SAFE OPERATIONBattery SafetyUse the following guideline

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 131Emergencies ALWAYS know the location of thenearest fire extinguisher. ALWAYS

PAGE 14 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)The DCA-220SSJ generator is equipped with a number of safety decals (Figures 2

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 151DCA-220SSJ — GENERATOR DECALSFigure 3. Generator Decals (Cont inued)

PAGE 16 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Figure 4. Typical Generator Grounding ApplicationDCA-220SSJ — INSTALLATION

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 171Outdoor InstallationInstall the generator in a area that is free of debris,byst

PAGE 18 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — GENERAL INFORMATIONDCA-220SSJ Whisperwatt™ Series Familiarization

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 191DCA-220SSJ — MAJOR COMPONENTSFigure 5. Major Components4elbaT. stnenopmoCrojaMr

PAGE 2 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)

PAGE 20 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — DIAGNOSTIC DISPLAYThe diagnostic display panel located inside the

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 211First Time Start Up1. When power is first applied to the diagnostic display,the

PAGE 22 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)2. The language choices will be displayed. Use the “Arrow”buttons to scroll th

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 231First Time Start Up1. When power is first applied to the diagnostic display,the

PAGE 24 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)2. The language choices will be displayed. Use the “Arrow”buttons to scroll th

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 2512. The main menu will pop up on the display. Use the “ArrowButtons” to scroll t

PAGE 26 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)!!!Indicates Auxiliary Gage FaultIndicates Fault WarningIndicates Derate or Sh

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 271Shut Down Codes1. During normal operation the single or four parameterscreen wi

PAGE 28 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)3. Once the “Adjust Backlight” menu item has beenhighlighted touch the “Enter

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 291Select Units1. Starting at the single or four engine parameter displaytouch the

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 31NOTE PAGE

PAGE 30 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)3. Once the “Setup 1-up Display” menu icon has beenhighlighted touch the “Ente

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 31111. Touch the “Enter Button” to deselect the selectedparameter removing it from

PAGE 32 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)COOL1800 RPM015003000TEMPENG RPM98%14.257 PSI1000 RPMLOAD RPMBATT VOLTENG RPMO

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 3319. The parameter that is highlighted is the selectedparameter for the screen. U

PAGE 34 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)4. Touch “Select” to enter the “Gage Data” display. When“Gage Data” is selecte

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 35111. Touch the “Menu” button to return to “Utilities” menu.Touch the “Menu butto

PAGE 36 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)GLOSSARY (Troubleshooting information)CANBUS FAILUREDiagnostic Display has not

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 371DCA-220SSJ — GENERATOR CONTROL PANELThe definitions below describe the controls

PAGE 38 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Figure 8. Engine Operating PanelDCA-220SSJ — ENGINE OPERATING PANELThe defini

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 391DCA-220SSJ — ENGINE OPERATING PANEL8. Engine Speed Switch – This switch control

PAGE 4 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)TABLE OF CONTENTSSpecification and partnumber are subject tochange without noti

PAGE 40 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Output Terminal FamiliarizationThe “Output Terminal Panel ” (Figure 8) is pro

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 411100 VAC GFCI ReceptaclesThere are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)

PAGE 42 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Figure 14. Connecting LoadsConnecting LoadsLoads can be connected to the gene

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 431DCA-220SSJ — LOAD APPLICATIONSingle Phase LoadAlways be sure to check the namep

PAGE 44 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — GENERATOR OUTPUTSGenerator AmperageTables 8 and 9 describe the g

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 451Maximum AmpsTable 10 shows the maximum amps the generator can pro-vide. DO NOT

PAGE 46 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Figure 21. Voltage Change-Over Board 240V ConfigurationUVWO

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 471DCA-220SSJ — OUTPUT TERMINAL PANEL CONNECTIONS2. Connect the load wires to the

PAGE 48 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — PRE-SETUPFigure 30. Engine Oil DipstickWhen checking the engine o

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 491DCA-220SSJ — PRE-SETUPRefueling Procedure:1. Level Tanks – Make sure fuel cells

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 51MQPOWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-537-3

PAGE 50 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Day-to-day addition of coolant is done from the recoverytank. When adding cool

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 511DCA-220SSJ — PRE-SETUPWhen connecting battery do the following:1. NEVER connect

PAGE 52 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Starting (Manual)1. Place the engine speed switch (Figure 41) in the “LOW ”(d

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 53110.Verify that the Engine Runningstatus LED on the MPEC unit(Figure 45) is ON

PAGE 54 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)When the generator is set in theAUTO mode, the generator willautomically start

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 5511. Perform steps 1 through 6 in the Before Starting sectionas outlined in the

PAGE 56 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Normal Shutdown ProcedureTo shutdown the generator use the following procedure

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 571DCA-220SSJ — MAINTENANCE (ENGINE)Service DailyIf the engine is operating in ver

PAGE 58 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — MAINTENANCE (ENGINE)Generator StorageFor longe term storage of t

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 591DCA-220SSJ — MAINTENANCE (HEATER/CHARGER)To ensure adequate startingcapability,

PAGE 6 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — SPECIFICATIONSsnoitacificepSrotareneG.1elbaTledoMUJSS022-ACDepyT,d

PAGE 60 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — MAINTENANCE (TRAILER )8. Tire Size - Indicates the diameter of th

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 611DCA-220SSJ — MAINTENANCE (TRAILER )Hydraulic Surge BrakesHydraulic surge brakes

PAGE 62 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcompone

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 631NEVER use an pneumatic airgun to tighten wheel lug nuts.Figure 62. Wheel Lug N

PAGE 64 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — TRAILER WIRING DIAGRAMFigure 63. Trailer/Towing Vehicle Wiring Di

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 651DCA-220SSJ — GENERATOR WIRING DIAGRAMFigure 64. Generator Wiring Diagram

PAGE 66 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — ENGINE WIRING DIAGRAMFigure 65. Engine Wiring Diagram

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 671Practically all breakdowns can be prevented by proper handling and maintenance

PAGE 68 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — TROUBLESHOOTING (ENGINE CONTROLLER)Practically all breakdowns can

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 691NOTE PAGE

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 71DCA-220SSJ — DIMENSIONS (TOP, SIDE AND FRONT)Figure 1. DimensionsSNOISNEMID.3ELB

PAGE 70 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — EXPLANATION OF CODE IN REMARKS COLUMNNOTEWhen ordering a part th

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 711DCA-220SSJ — SUGGESTED SPARE PARTSPart number on this Suggested Spare Parts lis

PAGE 72 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ — GENERATOR ASSY.GENERATOR ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 731DCA-220SSJ — GENERATOR ASSY.GENERATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS

PAGE 74 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)GENERATOR ASSY.DCA-220SSJ — GENERATOR ASSY. (CONT.)

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 751GENERATOR ASSY. (CONT.)NO. PART NO. PART NAME QTY. REMARKS10 0012110065 HEX. HE

PAGE 76 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— CONTROL PANEL ASSY.CONTROL PANEL ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 771DCA-220SSJ— CONTROL PANEL ASSY.CONTROL PANEL ASSY.NO. PART NO. PART NAME QTY.

PAGE 78 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— CONTROL BOX ASSY.CONTROL BOX ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 791DCA-220SSJ— CONTROL BOX ASSY.CONTROL BOX ASSY.NO. PART NO. PART NAME QTY. REMA

PAGE 8 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)This Owner's Manual has beendeveloped to provide completeinstructions for

PAGE 80 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)CONTROL BOX ASSY. (CONT.)DCA-220SSJ— CONTROL BOX ASSY. (CONT)

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 811DCA-220SSJ— CONTROL BOX ASSY. (CONT)CONTROL BOX ASSY.NO. PART NO. PART NAME QT

PAGE 82 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 831DCA-220SSJ— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.NO. PART NO. PART

PAGE 84 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 851DCA-220SSJ— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.NO. PART NO. PART

PAGE 86 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 871ENGINE AND RADIATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS70 0602021070 CAP 1

PAGE 88 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— OUTPUT TERMINAL ASSY.OUTPUT TERMINAL ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 891DCA-220SSJ— OUTPUT TERMINAL ASSY.OUTPUT TERMINAL ASSY.NO. PART NO. PART NAME QT

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 91DCA-220SSJ — SAFETY MESSAGE ALERT SYMBOLSALWAYS place the MPEC control switchin

PAGE 90 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— BATTERY ASSY.BATTERY ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 911DCA-220SSJ— BATTERY ASSY.BATTERY ASSY.NO. PART NO. PART NAME QTY. REMARKS1 0168

PAGE 92 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— MUFFLER ASSY.MUFFLER ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 931DCA-220SSJ— MUFFLER ASSY.MUFFLER ASSY.NO. PART NO. PART NAME QTY. REMARKS1 M433

PAGE 94 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— FUEL TANK ASSY.FUEL TANK ASSY.

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 951DCA-220SSJ— FUEL TANK ASSY.FUEL TANK ASSY.NO. PART NO. PART NAME QTY. REMARKS1

PAGE 96 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENCLOSURE ASSY.ENCLOSURE ASSY.THE SERIAL NUMBER MAY BE REQUIRED.A

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 971DCA-220SSJ— ENCLOSURE ASSY.ENCLOSURE ASSY.NO. PART NO. PART NAME QTY. REMARKS1

PAGE 98 — DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07)DCA-220SSJ— ENCLOSURE ASSY. (CONT.)ENCLOSURE ASSY. (CONT.)THE SERIAL NUMBER M

DCA-220SSJ— OPERATION AND PARTS MANUAL — REV. #1 (03/22/07) — PAGE 991DCA-220SSJ— ENCLOSURE ASSY. (CONT.)ENCLOSURE ASSY. (CONT.)NO. PART NO. PART NA