MQ Power DCA-220SSK User manual

© COPYRIGHT 2001, MULTIQUIP INC.
PARTS AND OPERATION MANUAL
Revision #0 (06/01/01)
MULTIQUIPINC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX:[phone]
310-537-3700
SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX:[phone] FAX:[phone]
E-mail:[email protected] •www:multiquip.com
MQ POWER
DCA-220SSK
WHISPERWATT
TM
GENERATOR
FOR
SUNBELT
S/N3703350 to 3703363
S/N 3703854 to 3703868
(For other Serial Numbers,
refer to standard or GEER manuals)
PARTS AND OPERATION MANUAL
PART LIST NO. C1875300104B
Table of Contents

PAGE 2 — DCA-220SSK — PARTS AND OPERATION MANUAL (SUNBELT)— REV. #0 (06/01/01)
Table of Contents

DCA-220SSK — PARTS AND OPERATION MANUAL (SUNBELT)— REV. #0 (06/01/01) — PAGE 3
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: [phone]
MAIN
800/421-1244 or 310/537-3700
FAX: [phone]
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PAGE 4 — DCA-220SSK — PARTS AND OPERATION MANUAL (SUNBELT)— REV. #0 (06/01/01)
TABLE OF CONTENTS
NOTE
Specification and part
number are subject to
change without notice.
Here's HowTo Get Help............................................... 3
Table Of Contents........................................................ 4
Parts Ordering Procedures .......................................... 5
Rules for Safe Operation .......................................... 6-9
Towing Safety Precaution .......................................... 10
Trailer Safety Guidelines....................................... 11-17
TrailerWiring Diagram ................................................ 18
Electric BrakeTroubleshooting .................................. 19
Hydraulic BrakeTroubleshooting................................ 20
Operation and Safety Decals................................ 21-24
DCA 220 Specifications ............................................ 25
GeneralInformation .............................................. 26-28
MajorComponents .................................................... 29
Dimensions........................................................... 30-31
ControlPanel Descriptions ................................... 32-33
Engine Operating Panel Descriptions ................... 34-35
OutputTerminal Panel Overview ........................... 36-43
Installation ............................................................ 42-43
Pre Setup ............................................................. 44-47
Load Application ........................................................ 48
GeneratorStart-up Procedure, Manual................. 49-53
Generator Start-up Procedure, Auto .......................... 54
GeneratorShut-DownProcedure ............................... 55
Maintenance ......................................................... 56-57
GeneratorWiringDiagram.......................................... 58
EngineWiring Diagram .............................................. 59
EngineTroubleshooting ......................................... 60-62
MPECTroubleshooting .............................................. 63
Explanation of Code in Remarks Column .................. 64
Suggested Spare Parts ............................................. 65
MQPower DCA 220SSK
AC Generator
Generator Assembly............................................. 66-69
Control Panel Assembly ....................................... 70-71
Control Box Assembly.......................................... 72-73
Engine & Radiator Assembly................................ 74-79
Engine Operating Panel Assembly ....................... 80-81
Governor Actuator Assembly ............................... 82-83
Output Terminal Assembly.................................... 84-85
Battery Assembly................................................. 86-87
Muffler Assembly ................................................. 88-89
Fuel Piping Assembly ......................................... 90-91
Jacket Water Heater Assembly ............................ 92-93
Enclosure Assembly ............................................ 94-99
Rubber Seal Assembly..................................... 100-101
Name Plate And Decals ................................... 102-105
Terms and Condition of Sale — Parts ..................... 106

DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01) —PAGE 5
PARTS ORDERING PROCEDURES
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■■
■ UPS Ground Service at no charge for freight
■■
■■
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Commonnuts, bolts and washers (all items under $1.00list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
For faxed orders only
UPS
Special
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-freenationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
■■
■■
■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 Ground
•UPS Second Day or Third Day*
•UPS Next Day*
•Federal Express Priority One (please provide us with your Federal
Express account number)*
•Airborne Express*
•Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Extra Fax Discount for
DomesticUSA Dealers
Only
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PAGE 6 —DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01)
RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engineorgenerator.
■ 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
topeople.The generatorenginegives off DEADLY carbon
monoxide gas.
■ High Temperatures –Allow the engine to cool before
adding fuel or performing service and maintenance
functions.Contact with
hot components cancauseserious
burns.
CAUTION:
Failure to follow instructions in this manual
may lead to serious injury or even death!
Thisequipmentis to be operatedby trained
andqualifiedpersonnelonly!Thisequipment
is for industrial use only.
Thefollowingsafetyguidelinesshouldalwaysbeusedwhen
operating the DCA-220SSK portable generator:
GENERAL SAFETY
■ DONOToperateorservicethisequipmentbefore
readingthisentiremanual.
■ This equipment should not be operated by
persons under 18 years of age.
■ NEVERoperatethisequipment withoutproper
protective clothing, shatterproof glasses,
steel-toed boots and other protective
devices required by the job.
■ NEVERoperatethisequipmentwhennotfeeling
wellduetofatigue,illnessor taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ 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.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
CAUTION :
■ Always use extreme CAUTION
when working with flammable liquids.
When refueling, stop the engine and
allow it to cool.DO NOT smokearound
or near the machine. Fire or explosion
could result from fuel vapors, or if fuel
is spilled on a hot engine.
■ NEVERoperate thegeneratorinan explosiveatmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
Always refuel in a well-ventilated area,
away from sparks and open flames.
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DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01) —PAGE 7
RULES FOR SAFE OPERATION
■ NEVER touch output terminals during operation.This is
extremely dangerous.
Always stop the machine when
contact with the output terminals.
CAUTION :
■ Backfeedto a utility systemcan 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.
Never use damaged or worn cables when
connecting power tools or 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
causedamagetothegeneratorandelectrical
shock.
CAUTION :DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficienttimefortheengineandgenerator
to cool before performing maintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engineishotwillresultinhighpressurized,boilingwater
to gush out of the radiator, therefore causing severe
scalding to any persons in the general area of the
generator.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
CAUTION :
CAUTION :
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PAGE 8 —DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01)
RULES FOR SAFE OPERATION
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ Alwaysservice aircleanerfrequentlytoprevent carburetor
malfunction.
■ Always disconnect the battery before performing service
onthe generator.
■ Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipmentshould be stored in aclean, dry locationout of
the reach of children.
■ DO NOT leavethe generatorrunning inthe manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in
Operator’sManualbeforeattemptingtooperateequipment.
■ Refertothe Komatsu EngineOwner's Manual forengine
technical questions or information.
Loading and Unloading (Crane)
■ Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■ Always drain fuel prior to lifting.
■ Always make sure crane or lifting device has been
properlysecured tothehook ofguardframeongenerator.
■ NEVER lift the machine while the engine is running.
■ Use adequate lifting cable (wire or rope) of sufficient
strength.
■ When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
■ NEVER allow any person or animal to stand underneath
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generatorduring transport.
1. DO NOT drop the battery.There is the possibility of risk
that the battery may explode.
2. 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.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Alwayskeepbatterychargingandboostercablesin good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
toavoidriskofadangerousconcentration ofcombustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plentyofwater,thencontactthenearestdoctororhospital,
and seek medical attention.
Battery
Neveroverfillthebatterywithwaterabove
the upper limit.
CAUTION :
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. Use
the following guidelines when handling the battery:
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DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01) —PAGE 9
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long
distances or bad roads.
■ Alwaystie-downthe generator duringtransportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Always know the location of the nearest fire
extinguisher
and first aid kit . Know the location of the
nearesttelephone.Alsoknowthephonenumbersofthe
nearest ambulance , doctor and fire department .
Maintenance Safety
■ NEVER lubricate components or attempt service on a
runningmachine.
■ 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.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
RULES FOR SAFE OPERATION
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PAGE 10 —DCA-220SSK —PARTS AND OPERATION MANUAL (SUNBELT)—REV. #0 (06/01/01)
DCA-220SSK —TOWING
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure1)thatsupportsthe generatorand the towing vehicle
are in good operating condition and both units are
mechanically sound.
Thefollowing list ofsuggestionsshouldbe used whentowing
yourgenerator:
CAUTION :
Towing Safety Precautions
■ ALWAYS attach trailer'ssafetychaintobumperoftowing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ Rememberthe maximum speedunlessotherwiseposted
for highway towing is 45 MPH. Recommended off-road
towing is not to exceed 10 MPH or less depending on
type of terrain.
■ Place chocked blocks underneath wheel to prevent
rolling, while parked.
■ Place support blocks underneath the trailer's bumper to
prevent tipping , while parked.
■ Use the trailer's hand winch to adjust the height of the
trailer, then insertlockingpin to lockwheelstandinplace,
whileparked.
■ Avoid sudden stops and starts.This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Checkwithyourcountyorstatesafetytowing
regulations department before towing your
generator.
■ Make sure the hitch and coupling of the towing vehicle
arerated equalto,orgreaterthan thetrailer"grossvehicle
weightrating" (GVWR).
■ ALWAYS inspectthehitchandcouplingforwear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS makesurethetraileris equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
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