MULTIQUIP WHISPERWATT DCA-220SSVU, Operation And Parts Manual

Page 1: ...S AND OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 0 04 18 06 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 220SSVU 50 Hz GENERATOR PARTS LIST NO M4870300...

Page 2: ...PAGE 2 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06...

Page 3: ...ions are based on the DCA 220SSVU 50 Hz WHISPERWATT AC Generator Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any...

Page 4: ...tputTerminal Panel Familiarization 24 26 Load Application 27 Generator Outputs 28 GaugeReading 29 OutputTerminal Panel Connections 30 31 Pre Setup 32 35 Generator Start up Procedure Manual 36 37 Gener...

Page 5: ...s 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 li...

Page 6: ...0 0 5 1 r o t c a F r e w o P 8 0 t h g i e W y r D g k 3 8 4 3 s b l 8 7 6 7 t h g i e W t e W g k 2 9 8 3 s b l 0 8 5 8 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 E G 1 4 7 D A T...

Page 7: ...I S N 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 7 0 1 n i 2 1 2 4 F m m 0 5 6 3 n i 0 7 3 4 1 B m m 5...

Page 8: ...KILLED or SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions Gasoline engine...

Page 9: ...he surrounding 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 gover...

Page 10: ...death NEVER 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 mai...

Page 11: ...the equipment 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...

Page 12: ...to gush 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 c...

Page 13: ...or less 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 t...

Page 14: ...cals 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...

Page 15: ...DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 15 1 DCA 220SSVU 50 HZ GENERATOR DECALS Figure 3 Generator Decals Cont inued...

Page 16: ...PAGE 16 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 Figure 4 Typical Generator Grounding Application DCA 220SSVU 50 HZ INSTALLATION...

Page 17: ...m2 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...

Page 18: ...ns of the open delta A B C and D Duringsteadystateloads thepowerfromthevoltageregulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to...

Page 19: ...y l b m e s s A l e n a P l a n 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...

Page 20: ...PAGE 20 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 NOTE PAGE...

Page 21: ...l Lugs 6 Voltmeter 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...

Page 22: ...PAGE 22 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 Figure 7 Engine Operating Panel DCA 220SSVU 50 HZ ENGINE OPERATING PANEL...

Page 23: ...If the generator is to be connected to a building s AC power source via a transfer switch isolation place the switch in the AUTO position In this position the generator will monitor the AC line outpu...

Page 24: ...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 Figure8 shownbelowislocated ontheright handside l...

Page 25: ...urrent on all three receptacles is dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Tu...

Page 26: ...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 220SSVU 50 HZ OUTPUT TERMINAL PANEL FAMILIARIZATION Over C...

Page 27: ...close 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 in...

Page 28: ...hange 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 Maximum Amps Table 9 shows t...

Page 29: ...s 17 and18 place the AC Volt meter Change Over Switch See Figures 19 and 20 to the W U position and the AC Ammeter Change Over Switch Figure 19 to the U or W position to read the output on the selecte...

Page 30: ...1 Jumperthevoltagechange overboardfor240Voperation as shown in Figure 21 Figure 22 UVWO Terminal Lugs 3 220V Connections 2 Connect the load wires to the UVWO terminals as shown in Figure 22 3 Turn th...

Page 31: ...iguration Figure 27 UVWO Terminal Lugs 3 440V Connections 1 440V UVWOTerminal OutputVoltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 26 2 Connect th...

Page 32: ...o the 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 t...

Page 33: ...er neck 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 Figu...

Page 34: ...off and the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the VOLVO Engine Owner s Manual Fan BeltTension A slack fan bel...

Page 35: ...ll 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 P...

Page 36: ...cles or the output terminal lugs as shown in Figure 13 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 4 The output termin...

Page 37: ...willindicatethespeedoftheengine when the generator is operating Undernormaloperatingconditions this speed is approximately 1600 RPM s 10 The coolanttemperaturegauge Figure 50 will indicate the coolan...

Page 38: ...ZARDS When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure that the engine will not fail due to a dead ba...

Page 39: ...nspect entire generator for any damage or loosening of components that may have occured during operation Emergency Shutdown Procedure 1 To shut down the engine in the event of an emergency switch the...

Page 40: ...rvice 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 3 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...

Page 41: ...l or after disassembling the fuel system bleed the system according to the following procedure See the VOLVOEngine Manual for details To restart after running out of fuel turn the switch to the ON pos...

Page 42: ...acles will ONLY function when commercial power has been supplied to them Figure 58 To apply commercial power to these receptacles a power cord of adequate size will be required SeeTable 6 When using t...

Page 43: ...ectors looms are provided with 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 Trai...

Page 44: ...aulicsurgebrakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with th...

Page 45: ...d loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 16 Figure 60 Major Suspension Components DCA 220SSVU 50 HZ TRAILER MAINTENA...

Page 46: ...ent of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 61 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate...

Page 47: ...DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 47 1 DCA 220SSVU 50 HZ TRAILERWIRING DIAGRAM Figure 62 Trailer Towing Vehicle Wiring Diagram...

Page 48: ...PAGE 48 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERATORWIRING DIAGRAM Figure 63 GeneratorWiring Diagram...

Page 49: ...DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 49 1 DCA 220SSVU 50 HZ ENGINEWIRING DIAGRAM Figure 64 Engine Wiring Diagram...

Page 50: ...n i t 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...

Page 51: ...l o o c 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...

Page 52: ...out of 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 ass...

Page 53: ...E RADIATOR LOWER 1 V866095 RADIATOR CAP 1 0605505070 FUEL CAP 1 V966846 V BELT SET MAIN S N 2071145377 AND BELOW 1 V966847 V BELT SET MAIN S N 2071145378 AND ABOVE 1 V873771 ALTERNATOR 12 VDC 1 V91468...

Page 54: ...PAGE 54 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERATOR ASSY GENERATOR ASSY...

Page 55: ...16045 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 03432...

Page 56: ...PAGE 56 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 GENERATOR ASSY DCA 220SSVU 50 HZ GENERATOR ASSY CONT...

Page 57: ...SKET 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 0...

Page 58: ...PAGE 58 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU CONTROL PANEL ASSY CONTROL PANEL ASSY...

Page 59: ...601840121 KNOB 1 12 ECU9988N220V CONTROLLER ECU 1 REPLACES P N 0602202545 13 0601831340 SWITCH 1 14 0027104035 MACHINE SCREW 2 14A 0207004000 HEX NUT 2 15 0601831395 ENGINE SPEED SWITCH 1 16 060183158...

Page 60: ...PAGE 60 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU CONTROL BOX ASSY CONTROL BOX ASSY...

Page 61: ...INAL PLATE 3 12 M4276300004 CHANGE OVER PLATE 6 13 M9220100104 TIE BOLT 13 14 M9220100104 TIE BOLT 13 15 0040010000 SPRINGWASHER 26 16 0041410000 PLAINWASHER 26 17 0016900030 HEX HEAD BOLT 4 18 060182...

Page 62: ...PAGE 62 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 CONTROL BOX ASSY CONT DCA 220SSVU CONTROL BOX ASSY CONT...

Page 63: ...04020 MACHINE SCREW 6 35 M4213600104 STOPPER CONTROL PANEL 1 36 0041206000 PLAINWASHER 1 37 0605010502 SNAP PIN 1 38 M4213500004 COVER CONTROL BOX 1 39 0016908020 HEX HEAD BOLT 8 40 M4213300004 SIDE P...

Page 64: ...PAGE 64 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 65: ...HEAD BOLT 8 4 0030012000 SPRINGWASHER 8 5 0605000011 RUBBER SUSPENSION 2 6 0030016000 HEX NUT 4 7 0040016000 SPRINGWASHER 4 8 0017112035 HEX HEAD BOLT 4 9 0030012000 HEX NUT 4 10 0040012000 SPRINGWAS...

Page 66: ...PAGE 66 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 67: ...G COOLANT PUMP 1 46 V1661993 THERMOSTAT 1 47 V471788 SEALING RING THERMOSTAT UPPER 1 48 V1544710 SEALING RING THERMOSTAT LOWER 1 49 V925092 O RING THERMOSTAT HOUSING 1 50 V843869 FAN RADIATOR 1 S N 20...

Page 68: ...U OUTPUTTERMINAL ASSY OUTPUT TERMINAL 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...

Page 69: ...2 13 0027104016 MACHINE SCREW 4 14 0601808803 CIRCUIT BREAKER SINGLE POLE 20A 2 15 0601808804 CIRCUIT BREAKER DOUPLE POLE 50A 3 16 M4260600104 BRACKET CIRCUIT BREAKER 1 16 1 0222100150 RUBBER CUSHION...

Page 70: ...PAGE 70 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU BATTERY ASSY BATTERY ASSY...

Page 71: ...ERY ASSY BATTERY ASSY NO PART NO PART NAME QTY REMARKS 1 0602220196 BATTERY 2 2 M9310500404 BATTERY SHEET 2 3 M9103000504 BATTERY BAND 2 4 0602220921 BATTERY BOLT SET 4 5 0040006000 SPRINGWASHER 4 6 M...

Page 72: ...PAGE 72 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU MUFFLER ASSY MUFFLER ASSY...

Page 73: ...AME QTY REMARKS 1 M4330100002 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M4333000003 EXHAUST PIPE 1 4 V424628 GASKET 1 REPLACES P N 0602320196 5 M4333200004 GASKET 1 6 0017112055 HEX HEAD BOLT 4 7 M4330...

Page 74: ...PAGE 74 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU FUELTANK ASSY FUEL TANK ASSY...

Page 75: ...000 HEX NUT 2 6 0222100720 RUBBER SHEET 4 7 M9200000003 DRAIN JOINT 1 8 M9200200004 DRAIN BOLT 1 9 0150000018 O RING 1 10 0016906020 HEX HEAD BOLT 2 11 M1363400104 DRAIN HOSE 1 12 0605515198 HOSE BAND...

Page 76: ...220SSVU 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 WHIT...

Page 77: ...00103 OVER COVER FRONT FRAME 1 11 0016908020 HEX HEAD BOLT 14 12 M4433000002 CENTER FRAME 1 13 0010114050 HEX HEAD BOLT 4 13A 0030014000 HEX NUT 4 13B 0040014000 SPRINGWASHER 4 13C 0041214000 PLAINWAS...

Page 78: ...VU 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...

Page 79: ...003 SIDE DOOR 1 36A M4493400004 ACOUSTIC SHEET 1 37 M4453000103 SIDE DOOR 1 37A M4493400104 ACOUSTIC SHEET 1 38 M4453000303 SIDE DOOR 1 38A M4493400304 ACOUSTIC SHEET 1 39 M4453000203 SIDE DOOR 1 39A...

Page 80: ...PAGE 80 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU RUBBER SEALS ASSY RUBBER SEALS ASSY...

Page 81: ...0229201300 SEAL RUBBER 4 2 0228901010 SEAL RUBBER 4 3 0228901200 SEAL RUBBER 4 4 0228901050 SEAL RUBBER 3 5 0228900600 SEAL RUBBER 2 6 0229200950 SEAL RUBBER 1 7 0228901230 SEAL RUBBER 2 8 0229201200...

Page 82: ...PAGE 82 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY...

Page 83: ...VING PARTS 3 M90300000 3 4 M9503000103 DECAL WATER OIL CHECK 1 M90300010 3 5 M9503100004 DECAL WARNING HOT COOLANT 1 M90310000 3 6 M9510100004 DECAL CAUTION HOT PARTS 1 M91010000 OUTPUTTERMINAL GROUP...

Page 84: ...icants g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pendin...

Page 85: ...DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 85 1 NOTE PAGE...

Page 86: ...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 co...