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PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
DCA-220SSK
TM
WHISPERWATT
GENERATOR
(Standard)
Up to S/N3696500
S/N3699150 to S/N3699619
S/N3699637 to S/N3703349
S/N3703364 to S/N3703853
S/N3703869~
(For serial numbers not listed, please refer to Sunbelt or GEER manuals)
Revision #3 (06/05/01)
MULTIQUIP INC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700 SERVICE DEPARTMENT:
800-421-1244 800-835-2551
FAX: 310-537-3927 F
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PAGE 2 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
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HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING PARTS DEPARTMENT 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284 SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX: 310/638-8046 MAIN 800/421-1244 or 310/537-3700 FAX: 310 - 537-3927 DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 3
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TABLE OF CONTENTS Here's How To Get Help ........................................ 3 DCA-220SSK GENERATOR Table Of Contents ................................................. 4 Parts Ordering Procedures ................................... 5 Generator Assembly-Up to S/N1337562 ............... 70-73 Rules for Safe Operation ...................................... 6-9 Generator Assembly-S/N1337563~ ...................... 74-77 Towing Safety Precaution ..................................... 10 Control B
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PARTS ORDERING PROCEDURES 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
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RULES FOR SAFE OPERATION CAUTION: Failure to follow instructions in this manual NEVER touch the hot exhaust may lead to serious injury or even death! manifold, muffler or cylinder. Allow This equipment is to be operated by trained these parts to cool before servicing and qualified personnel only! This equipment engine or generator. is for industrial use only. The following safety guidelines should always be used when operating the DCA-220SSK portable generator: High Temperatures – Allow the
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RULES FOR SAFE OPERATION CAUTION: CAUTION: DO NOT touch or open any of the below mentioned components while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance. NEVER touch output terminals during operation. This is Radiator extremely dangerous. Always stop the machine when 1. Radiator Cap - Removing the radiator cap while the contact with the output terminals. engine is hot due to high pressure, will result in boiling wat
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RULES FOR SAFE OPERATION Battery ! NEVER Run engine without air filter. Severe engine damage may occur. CAUTION: ! Always service air cleaner frequently to prevent carburetor Never over fill the battery with water above malfunction. the upper limit. ! Always disconnect the battery before performing service on the generator. ! Always be sure the operator is familiar with proper safety The battery contains acids that can cause injury to the eyes precautions and operations techniques before using
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RULES FOR SAFE OPERATION Transporting Maintenance Safety Always shutdown engine before transporting. NEVER lubricate components or attempt service on a running machine. Tighten fuel tank cap securely. Always allow the machine a proper amount of time to Drain fuel when transporting generator over long cool before servicing. distances or bad roads. Keep the machinery in proper running condition. Always tie-down the generator during transportation by securing the generator. Fix dama
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DCA-220SSK — TOWING Towing Safety Precautions ALWAYS attach trailer's safety chain to bumper of towing vehicle. CAUTION : ALWAYS make sure the vehicle and trailer directional, Check with your county or state safety towing backup, brake, and trailer lights are connected and regulations department before towing your working properly. generator. Remember the maximum speed unless otherwise posted for highway towing is 45 MPH. Recommended off-road To reduce the possibility of an accident towin
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DCA-220SSK — TRAILER-SAFETY GUIDELINES CAUTION: 4. Frame Length - This measurement is from the ball hitch to the rear bumper (reflector). ALWAYS make sure the trailer is in good 5. Frame Width - This measurement is from fender to operating condition. Check the tires for fender. proper inflation and wear. Also check the 6. Jack Stand - Trailer support device with maximum wheel lug nuts for proper tightness. pound requirement from the tongue of the trailer. 7. Coupler - Type of h
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DCA-220SSK — TRAILER-SPECIFICA TIONS Table 1. Specifications MODEL APPLICATION FUEL BRAKE GVWR FRAME FRAME JACK CELL SYSTEM LENGTH WIDTH STAND TRLR-10-15 TLG-12, DCA15,NO O NS1" 900LB 9" 6 5. 0 800LB TLW-300 FULL TILT WHEEL TRLR-10X TLG-12, DCA15,NO O NS1" 900LB 9" 6 5. 0 800LB TLW-300 FULL TILT WHEEL TRLR-10XF TLG-12, DCA15,5O 1 GAL NS1" 900LB 9" 6 5. 0 800LB TLW-300 FULL TILT WHEEL TRLR-225W DO CA-10 NONS2" 200LB 8" 5 4. 2 800LB FULL TILT WHEEL BLW-400 BO LW-400NCES LECTRI2" 700LB W/MAST 154
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DCA-220SSK — TRAILER-SPECIFICA TIONS Table 1. Specifications (Con't) MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL TRLR-10-15W 2" BALL CLASS1" 75-13C12 3"X4.502G 200# 2X5F LU3/ LEA 4 WIRE LOOM W 2 ADJUSTABLE 4 POLE FLAT TRLR-10X 2"BALL CLASS1" 75-13C12 3"X4.52G 200#2X5F LU3T LEA 4 POLE FLA 2 ADJUSTABLE TRLR-10XF 2"BALL CLASS1" 75-13C12 3"X4.52G 200#2X5F LU3T LEA 4 POLE FLA 2 ADJUSTABLE TRLR-225W 2"BALL CLASS1" 75-13B12 3X4.52G 200#2X5X LUQT FLE 4 POLE FLA 2 ADJUSTABLE BLW 400 2"BAL
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DCA-220SSK — TRAILER SAFETY GUIDELINES Brakes Before any brake synchronizations adjustments can be made, If your trailer has a braking system, the brakes should be the trailer brakes should be burnished-in by applying the inspected the first 200 miles of operation. This will allow the brakes 20-30 times with approximately a 20 m.p.h. decrease brake shoes and drums to seat properly. After the first 200 in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for mile interval, inspect the brake
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DCA-220SSK — TRAILER SAFETY GUIDELINES Figure 2. Electrical Brake Components Hydraulic/Air/Surge Brakes components that will require inspection and maintenance. Hydraulic brakes (Figure 3) should not require any special Inspect these components as required using steps 1 through attention with the exception of routine maintenance such as 6 as referenced in the electric brake adjustments section. shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. B
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DCA-220SSK — TRAILER SAFETY GUIDELINES Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched. CAUTION: DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force
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DCA-220SSK — TRAILER SAFETY GUIDELINES Table3. SuspensionTorqueRequirements Item Torque(Ft.-Lbs.) 35 /8"U-BOLT MIN-30MAX-3 70 /16"U-BOLT MIN-45MAX-6 10 /2"U-BOLT MIN-45MAX-6 SHACKLE BOLT SNUG FIT ONLY. PARTS MUST ROTATE FREELY. SPRING EYE BOLT LOCKINGNUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT-BOLT ASSEMBLY. SHOULDER TYPE MIN-30MAX-50 SHACKLE BOLT Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the
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DCA-220SSK — TRAILER-WIRING DIAGRAM NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT PAGE 18 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
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DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING Table5.ElectricBrakeTroubleshooting Symptom PossibleCause Solution N? oBrakesorIntermittentBrakesA. nyopencircuitsorbrokenwires Findandcorrect A. nyshortcircuits? Findandcorrect F. aultycontroller? Testandcorrect A. nylooseconnections? Findandrepair G. roundwiresecure? Findandsecure WeakBrakesorBrakesPulltoG. reaseoroilonmagnetsorlinings? Cleanorreplace OneSide Ce onnectionscorroded? Cleanandcorrectcaus ofcorrosion. B. rakedrumsscoredorgrooved? Machine
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DCA-220SSK — TRAILER-BRAKE TROUBLESHOOTING Table6.HydraulicBrakeTroubleshooting Symptom PossibleCause Solution N? oBrakesB. rakelinebrokenorkinked Repairorreplace WeakBrakesorBrakesPulltoB. rakeliningglazed? Reburnishorreplace OneSide T. raileroverloaded? Correctweight B. rakedrumsscoredorgrooved? Machineorreplace T. irepressurecorrect? Inflatealltiresequally T. iresunmatchedonthesameaxle? Matchtires L? ockingBrakesB. rakecomponentsloose,bentorbroken Replacecomponents B. rakedrumsout-of-round?
