Multiquip DCA220SSCU4i Operation And Parts Manual

OperatiON aND parts MaNUaL

®

WhisperWatt™ series

MODeL DCa220ssCU

MODeL DCa220ssCU4i

60hz GeNeratOr

(CUMMiNs QsB7-G6 DieseL eNGiNe)

parts List NO. M4870300204

Revision #0 (10/25/12)

To find the latest revision of this publication, visit our website at: www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

prOpOsitiON 65 WarNiNG

Diesel engine exhaust and some of

page 2 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

repOrtiNG safety DefeCts

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety

Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-

327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 3

DCa220ssCU/ssCU4i

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ......................................... 3

Table Of Contents .................................................... 4

Safety Information .............................................. 6-11

Specifications ........................................................ 12

Dimensions ............................................................ 13

Installation ........................................................ 14-15

General Information ............................................... 16

Major Components ................................................ 17

Engine Control Unit (ECU) .................................... 18

Engine/Generator Control Panel............................ 19

Output Terminal Panel Familiarization .............. 20-22

Load Application .................................................... 23

Generator Outputs ................................................. 24

Generator Outputs/Gauge Reading ....................... 25

Output Terminal Panel Connections ................. 26-27

Inspection/Setup ............................................... 28-31

Generator Start-Up Procedure (Manual) .......... 32-33

Generator Start-Up Procedure (Auto Mode) .......... 34

Generator Shut-Down Procedures ........................ 35

Maintenance ..................................................... 36-41

Trailer Maintenance .......................................... 42-45

TTrailer Wiring Diagram ......................................... 46

Generator Wiring Diagram ..................................... 47

Engine Wiring Diagram .......................................... 48

Troubleshooting (Generator) .................................. 49

Troubleshooting Diagnostics ................................. 50

Explanation of Code in Remarks Column.............. 52

Suggested Spare Parts ......................................... 53

taBLe Of CONteNts

Component Drawings

Generator Assembly ......................................... 54-57

Control Panel Assembly ................................... 58-59

Control Box Assembly ...................................... 60-63

Engine And Radiator Assembly ........................ 64-65

Output Terminal Assembly ................................ 66-67

Battery Assembly.............................................. 68-69

Muffler Assembly .............................................. 70-71

Fuel Tank Assembly .......................................... 72-73

Enclosure Assembly ......................................... 74-79

Rubber Seals Assembly ................................. 80-81

Nameplate And Decals Assembly .................... 82-85

Terms And Conditions Of Sale — Parts ................ 86

NOTICE

Specifications are subject to change without notice.


NOtes


Do not operate or service the equipment before reading the entire manual. 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.

saFeTY messages

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifi cally address the level of exposure to the operator and are preceded by one of four words:

danger, Warning, cauTion or noTice. saFeTY sYmBols

danger

Indicates a hazardous situation which, if not avoided,

Will result in deaTh or serious inJurY.

safety iNfOrMatiON

Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Warning


could result in deaTh or serious inJurY.

cauTion


could result in minor or moderaTe inJurY.

NOTICE

Addresses practices not related to personal injury.


general saFeTY

cauTion

never operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.


never use accessories or attachments that are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

 alWaYs know the location of the nearest fi re extinguisher.

 alWaYs know the location of the nearest fi rst aid kit.

alWaYs know the location of the nearest phone or keep a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and

fi re department. This information will be invaluable in the case of an emergency.

never operate this equipment when not feeling well due to fatigue, illness or when under medication.

never operate this equipment under the infl uence of drugs or alcohol.

alWaYs check the equipment for loosened threads or bolts before starting.

do noT use the equipment for any purpose other than its intended purposes or applications.

NOTICE

This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.

Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation will void all warranties.

generaTor saFeTY

danger

 never operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fi re could result causing severe bodily harm or even death.

Warning

never disconnect any emergency or safety devices.

These devices are intended for operator safety.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties.

cauTion

never lubricate components or attempt service on a running machine.

NOTICE

alWaYs ensure generator is on level ground before use.

alWaYs keep the machine in proper running condition.

Fix damage to machine and replace any broken parts immediately.

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 and unauthorized personnel dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 7

engine saFeTY

danger

The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free fl ow of cooling air. never operate this equipment in any enclosed or narrow area where free fl ow of the air is restricted. If the air fl ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

Warning

do noT place hands or fingers inside engine compartment when engine is running.

never operate the engine with heat shields or guards removed.

Keep fi ngers, hands hair and clothing away from all moving parts to prevent injury.

do noT remove the radiator cap while the engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

do noT remove the coolant drain plug while the engine is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

do noT remove the engine oil drain plug while the engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

cauTion

never touch the hot exhaust manifold, muffl er or cylinder. Allow these parts to cool before servicing equipment.


NOTICE

never run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter frequently to prevent engine malfunction.

never tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.

Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without suffi cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

In order for a diesel engine to operate at peak effi ciency, it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel.

Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

State Health Safety Codes and Public Resources

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or fl ames from the engine exhaust. Spark arresters are qualifi ed and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.


Fuel saFeTY

danger

do noT start the engine near spilled fuel or combustible fl uids. Diesel fuel is extremely fl ammable and its vapors can cause an explosion if ignited.

alWaYs refuel in a well-ventilated area, away from sparks and open fl ames.

alWaYs use extreme caution when working with

fl ammable liquids.

do noT fi ll the fuel tank while the engine is running or hot.

do noT overfi ll tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated areas and away from sparks and fl ames.

never use fuel as a cleaning agent.

do noT smoke around or near the equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

ToWing saFeTY

cauTion

Check with your local county or state safety towing regulations, in addition to meeting

Department of Transportation (DOT)

Safety Towing Regulations, before towing your generator.

Refer to MQ Power trailer manual for additional safety information.

In order 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 mechanically sound and in good operating condition.

alWaYs shutdown engine before transporting


Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.”

alWaYs inspect the hitch and coupling for wear. never tow a trailer with defective hitches, couplings, chains, etc.

Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be inﬂ ated to 50 psi cold.

Also check the tire tread wear on both vehicles.

 alWaYs make sure the trailer is equipped with a safety chain.

alWaYs properly attach trailer’s safety chains to towing vehicle.

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.

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.

Avoid sudden stops and starts. This can cause skidding, or jack-knifi ng. Smooth, gradual starts and stops will improve towing.

Avoid sharp turns to prevent rolling.

Trailer should be adjusted to a level position at all times when towing.

Raise and lock trailer wheel stand in up position when towing.

Place chock 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 swivel jack to adjust the trailer height to a level position while parked. dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 9

elecTrical saFeTY

danger

 do noT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers oFF before performing maintenance on the generator or making contact with output terminals.

 never insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or

death.

Backfeed to a utility system can cause

electrocution and/or property damage.

never connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious injury or even death.

power cord/cable safety

danger

never let power cords or cables lay in water.

never stand in water while AC power from the generator is being transferred to a load.

never use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation.

 never grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death.


Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.

NOTICE

alWaYs make certain that proper power or extension cord has been selected for the job. See Cable Selection

Chart in this manual.

grounding safety

danger

alWaYs make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) 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.

never use gas piping as an electrical ground.


BaTTerY saFeTY

danger

do noT drop the battery. There is a possibility that the battery will explode.

do noT expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur.

Warning

alWaYs wear safety glasses when handling the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

Use well-insulated gloves when picking up the battery.

alWaYs keep the battery charged. If the battery is not charged, combustible gas will build up.

alWaYs recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses.

If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

cauTion

alWaYs disconnect the negaTive battery terminal before performing service on the generator.

alWaYs keep battery cables in good working condition.

Repair or replace all worn cables.

safety iNfOrMatiON environmenTal saFeTY

NOTICE

Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel fi lters.

do noT use food or plastic containers to dispose of hazardous waste.

do noT pour waste, oil or fuel directly onto the ground, down a drain or into any water source.


speCifiCatiONs

model

Type

Table 1. generator specifications

DCA220SSCU/ DCA220SSCU4i

Revolving field, self ventilated, open protected type synchronous generator star with neutral armature connection phase standby output prime output

3Ø voltage (l-l/l-n) voltage change-over Bd. at 3Ø 240/139

3Ø voltage (l-l/l-n) voltage change-over Bd. at 3Ø 480/277

1Ø voltage (l-l/l-n) voltage change-over Bd. at 1Ø 240/120 power Factor

Frequency speed aux. ac power aux. voltage/output dry Weight

Wet Weight model

3

194 kW (242 kVA)

176 kW (220 kVA)

208Y/120, 220Y/127, 240Y/139

416Y/240, 440Y/254, 480Y/277

240/120

0.8

60 Hz

1800 rpm

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

6,636 lbs. (3,010 kg)

7,496 lbs. (3,400 kg)

Table 2. engine specifications

Cummins QSB7-G6 EPA Interim Tier 4 Certified

Type no. of cylinders

Bore x stroke displacement rated output starting coolant capacity lube oil capacity lubricating Type oil

Fuel Type

Fuel Tank capacity

Fuel consumption

Battery

1 Includes engine and radiator hoses

2 Includes filters

4 cycle, water-cooled, direct injection, turbo-charged air cooled and EGR

6 cylinders

4.21 in. x 4.88 in. (107 mm x 124 mm)

409 cu. in. (6.7 liter)

282 HP at 1800 rpm

Electric

11.4 gal. (43.0 liters) 1

4.6 gal. (17.5 liters) 2

API service class CJ-4 SAE 15W-40

#2 Diesel Fuel (Ultra low sulfur diesel fuel only)

100 gal. (380 liters)

12.4 gal. (46.8 L)/hr at full load 9.5 gal. (36.0 L)/hr at 3/4 load

6.9 gal. (26.0 L)/hr at 1/2 load 4.4 gal. (16.8 L)/hr at 1/4 load

27 (CCA 0°F 800A) X 2 page 12 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

TOP VIEW

B

C

MAXIMUM

LIFTING

POINT

14,050 lbs.

(6,373 kg)

E

DiMeNsiONs

D

A

220

SIDE VIEW

FRONT VIEW

F

Figure 1. Dimensions

G reference letter

A

B

C

D

Table 3. dimensions dimension in. (mm) reference letter dimension in. (mm)

31.10 in. (790 mm)

31.10 in. (790 mm)

41.33 in. (1,050 mm)

41.33 in. (1,050 mm)

E

F

G

H

41.33 in. (1,050 mm.)

137.79 in. (3,500 mm)

68.89 in. (1,750 mm)

51.18 in. (1,300 mm)

H dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 13

iNstaLLatiON

Figure 2. Typical Generator Grounding Application page 14 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

ouTdoor insTallaTion

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

cauTion

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

indoor insTallaTion

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall.

Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

mounTing

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). do noT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

iNstaLLatiON generaTor grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good earTh ground (Figure 2).

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.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 8 AWG (5.3 mm 2 ) b. Aluminum - 6 AWG (8.4 mm 2 )

2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system alWaYs consult with a licensed electrician.

NOTICE

This generator has a permanent bonding conductor between the generator stator windings and the frame.


generaTor

This generator (Figure 3) is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

operaTing panel

The “Operating Panel” is provided with the following:

ECU Controller

Gauge Unit Assembly

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge

• Tachometer

Panel Light/Panel Light Switch

Hour Check Button

Auto Start/Stop Switch

Engine Speed Switch

Emergency Stop Button

Water Temperature Gauge

conTrol panel

The “Control Panel” is provided with the following:

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

3-Pole, 600 amp Main Circuit Breaker

“Control Box” (located behind Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

ouTpuT Terminal panel

The “Output Terminal Panel” is provided with the following:

Three 120/240V output receptacles (CS-6369), 50A

Three auxiliary circuit breakers, 50A

Two 120V output receptacles (GFCI), 20A

Two GFCI circuit breakers, 20A

Eight output terminal lugs (3Ø power)

Ground lug

Battery Charger (Optional)

Jacket Water Heater (Optional)

GeNeraL iNfOrMatiON open delTa exciTaTion sYsTem

Each generator is equipped with the state of the art “open-

delta” excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and

D. During steady state loads, the power from the voltage regulator 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 the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “fixed ceiling” and responds according the demands of the required load.

engine

This generator is powered by a 6 cylinder, 4-cycle water cooled, direct injection, turbocharged, air cooled Cummins

QSB7-G6 diesel engine. This engine is designed to meet every performance requirement for the generator.

Reference Table 2 for engine specifications.

In keeping with MQ Power’s policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

elecTric governor sYsTem

The electric governor system controls the RPMs of the engine.

When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

exTension caBles

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.


1

MajOr COMpONeNts

2

220

3

4 6

220

U V W O GND

5

9

10

7

11

25

50

75

PSI 100

OIL PRESS

180

100

140

°F

220

260

WATER TEMP

½

E

FUEL

18

12

VOLTS

24

30

BATTERY

60

120 150 180

RPMX10

210

SPEED

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Option Program/

Exit

INCREASE DECREASE

V

U

OFF

W

V-W

U-V

OFF

W-U

Denyo

8

Table 4. generator major components iTem no.

1 descripTion

Muffler Assembly

5

6

7

2

3

4

Enclosure Assembly

Generator Assembly

Battery Assembly

Engine Assembly

Fuel Tank Assembly

Output Terminal Assembly

8

9

10

11

Circuit Breaker Assembly

Auto Start/Stop Controller Assembly

Gauge Unit Assembly

Operating Panel Assembly

Figure 3. Major Components dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 17

eNGiNe CONtrOL UNit (eCU)

1

ECU


A

Engine Started

Shutdown

Pre-Alarm

B

C

D

0

25

50

75

PSI

100

OIL PRESS

140

180

220

°F

100 260

WATER TEMP

6

12

18

VOLTS

24

30

BATTERY

E

½

°F

F

FUEL

0

60

120

150

180

RPMX10

210

SPEED

ECU


Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

INCREASE DECREASE

V

U

OFF

W

V-W

U-V

OFF

W-U

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

E F G H

The definitions below describe the controls and functions of the Engine Control Unit (Figure 4).

1. ecu controller — This auto start/stop controller displays the parameters and the diagnostic troubleshooting messages of the engine, and controls

DPF regeneration.

A. ecu display screen — Engine fault diagnostic messages are shown on this LCD display. screen

B. engine started lamp — This lamp when lit indicates engine is operating normally.

C. engine shutdown lamp — When an engine failure has occured this lamp will blink. Indicating the engine has been shutdown. The diagnostic fault message will be displayed on the LCD screen.

D. pre alarm lamp — When an engine failure has occured this lamp will blink. Indicating a pre-fault engine condition and the possibility of engine shutdown.The diagnostic fault message will be displayed on the LCD screen

Figure 4. Engine Control Unit (ECU)

E. alarm acknowledge Button — When the engine experiences a fault, the "Pre Alarm Lamp" or the

"Shutdown Lamp" will start blinking. Pushing this button will confirm the fault message and the blinking lamp will change to a solid lamp display.

The fault message will be displayed on the screen.

When multiple engine faults occur, the lamp will continue blnking until all fault messages are confirmed. The blinking lamp will change to a solid lamp display all current confirmed fault messages will scrool across the screen.

F. screen change Button — When this button is pushed during operation, the screen will cycle through each parameter screen.

G. option Button — This button is not active. Do not use.

H. program/exit Button — Pushing this button allows the DPF Force Regen and diagnostic code to be confirmed.


eNGiNe/GeNeratOr CONtrOL paNeL

1

0

25

50

75

PSI

100

A

OIL PRESS

100

140

180

220

°F

260

B

6

12

18

24

VOLTS

30

C

WATER TEMP BATTERY

D

E

½

°F

F

FUEL

E

0

60

120

150

180

RPMX10

210

SPEED

2

0

25

50

PSI

75

100

OIL PRESS

100

140

180

220

°F

260

WATER TEMP

E

½

°F

F

FUEL

6

12

18

24

VOLTS

30

BATTERY

0

60

120

150

180

RPMX10

210

SPEED

ECU


Engine Started

Shutdown

Pre-Alarm

5

3

4

7

INCREASE

V

U

OFF

W

DECREASE

8

9

V-W

U-V

OFF

W-U

14

6

Alarm Screen

Acknowledge Change

Option

Program

Exit

13

10

12

11

The definitions below describe the controls and functions of the Engine/Generator Control Panel (Figure 5).

1. gauge unit assembly — This assembly houses the various engine monitoring gauges. These gauges indicate: oil pressure, water temperature, charging voltmeter, fuel and engine speed RPM (tachometer).

A. oil pressure gauge — During normal operation this gauge be should read between 35 to 65 psi.

(241~448 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

B. Water Temperature gauge — During normal operation this gauge be should read between 180° and 225°F (82°~107°C).

C. charging voltmeter gauge — During normal operation this gauge indicate minimum 26 VDC

D. Fuel gauge — Indicates amount of diesel fuel available.

E. Tachometer — Indicates engine speed in RPM’s for 60 Hz operation. This meter should indicate

1800 RPM’s when the rated load is applied. .

2. panel light — For operation at night, panel light illuminates control panel for ease of reading meters and gauges. Make sure oanel light switch is in the OFF position when light is not in use.

3. panel light switch — When activated will turn on control panel light.

4. Frequency meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz

Figure 5. Gauge Unit Assembly

5. ac ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

6. ac voltmeter — Indicates the output voltage present at the u,v, and W output Terminal lugs.

7. voltage regulator control — Allows ±15% manual adjustment of the generator’s output voltage.

8. ammeter change-over switch — This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

9. 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.

10. emergency stop Button — Push this button inward to stop the engine in the event of an emergency. do

noT use this button as a means of stopping the engine.

11. engine speed switch — This switch controls the speed of the engine (low/high).

12. auto/start switch — This switch selects either manual or automatic operation . Center position is OFF (reset).

13. hour check Button — With the engine stopped, press and hold ths button. The total running hours, fuel level, and battery voltage will be displayed.

14. main circuit Breaker — This three-pole, 600 amp main breaker is provided to protect the u,v, and W

output Terminal lugs from overload.


OUtpUt terMiNaL paNeL faMiLiariZatiON ouTpuT Terminal panel

The Output Terminal Panel (Figure 7) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds

ouTpuT Terminal FamiliarizaTion

The “Output Terminal Panel ” (Figure 7) is provided with the following:

Three (3) 240/139V output receptacles @ 50 amp

Three (3) Circuit Breakers @ 50 amps

Two (2) 120V GFCI receptacles @ 20 amp

Two (2) GFCI Circuit Breakers @ 20 amps

Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

U V W

NEUTRAL

TERMINAL

GROUND

TERMINAL

HARD WIRE

HOOKUP PANEL

O

BLACK RED BLUE WHITE GREEN

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

CIRCUIT BREAKERS

FOR CS-6369 TWIST

LOCK RECEPTACLES

120 VAC, 20 AMP

GFCI RECEPTACLES

Y

W

X

CS-6369

TWIST-LOCK

AUX. POWER RECEPTACLES

240/139V, 50 AMPS

Figure 6. Output Terminal Panel page 20 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

OUtpUt terMiNaL paNeL faMiLiariZatiON

120 vac gFci receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over

board configuration. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output

(current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the

GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the output terminal lugs.

Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. Voltage Regulator Control Knob

Figure 7. G.F.C.I. Receptacle

Twist lock dual voltage 120/240 vac receptacles

There are three 240/139V, 50 amp auxiliary twist-lock (CS-

6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage change-over board is configured for

single-phase 240/120 application

Figure 8. 240/139V Twist-Lock Auxiliary

Receptacles dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 21

OUtpUt terMiNaL paNeL faMiLiariZatiON connecting loads

Loads can be connected to the generator by the output

Terminal lugs or the convenience receptacles (Figure 10).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, 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.

over current relay

An over current relay (Figure 11) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 10. Connecting Loads

NOTICE

Figure 11. Over Current Relay

Remember the overcurrent relay monitors the current flowing from the u,v, and W output Terminal lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 600 amp main breaker.

To restore power to the output Terminal panel, press the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (on).


single phase load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require

130—150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

Table 5. power Factor By load

Type of load power Factor

Single-phase induction motors

Electric heaters, incandescent lamps

Fluorescent lamps, mercury lamps

Electronic devices, communication equipment

Common power tools

0.4-0.75

1.0

0.4-0.9

1.0

0.8

2.5

5

7.5

10

15

20

Table 6. cable selection (60 hz, single phase operation) current in amperes load in Watts at 100 volts

300 at 200 volts

600

600

900

1200

1200

1800

2400 maximum allowable cable length

#10 Wire #12 Wire #14 Wire #16 Wire

1000 ft.

500 ft.

350 ft.

250 ft.

600 ft.

300 ft.

200 ft.

150 ft.

375 ft.

200 ft.

125 ft.

100 ft.

1800

2400

3600

4800

150 ft.

125 ft.

100 ft.

75 ft.

65 ft.

50 ft.

CAUTION: Equipment damage can result from low voltage

250 ft.

125 ft.

100 ft.

LOaD appLiCatiON

Three phase load

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732

NOTICE

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

danger

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.


generaTor ouTpuT volTages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the voltage change-over board

(Figure 12). To obtain some of the voltages as listed in

Table 7 (see below) will require a fine adjustment using the voltage regulator (VR) control knob located on the control panel.

voltage change-over Board

The voltage change-over board (Figure 12) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

GeNeratOr OUtpUts maximum amps

Table 8 shows the maximum amps the generator can provide. do noT exceed the maximum amps as listed.

Table 8. generator maximum amps model rated voltage dca220sscu/ dca220sscu4i maximum amps

Single Phase 120 Volt 488.9 amps (4 wire)

Single Phase 240 Volt 244.4 amps (4 wire)

Three Phase 240 Volt 529 amps

Three Phase 480 Volt 264 amps

Figure 12. Voltage Change-Over Board

cauTion

never attempt to place jumper plates on the voltage

change-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!

uvWo output

Terminal lugs

Table 7. voltages available voltage change-over Board

3-phase 240/139v position voltage change-over Board

3-phase 480/270v position

3Ø line-line 208V 220V 240V 416V 440V

1Ø line-neutral 120V 127V 139V 240V 254V voltage change-over Board single-phase 240/120v position

1Ø line-neutral/ line-line

N/A N/A N/A

480V

277V

N/A page 24 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

GeNeratOr OUtpUts/GaUGe reaDiNG hoW To read The ac ammeTer and ac volTage gauges

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and

do noT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

Before taking a reading from either gauge, configure the

Voltage Change-Over Board (Figure 13) which produces the desired output voltage.

ac ammeter gauge reading

Place the AC Ammeter Change-Over Switch (Figure 16) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter

Gauge (Figure 17). This process can be repeated for terminals V and W.

Figure 16. AC Ammeter

Change-Over Switch

Figure 17. AC Ammeter

(Amp reading on U Lug)

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 13. Voltage Change-Over Board

240/3 Ø Position

ac voltmeter gauge reading

Place the AC Voltmeter Change-Over Switch (Figure 14) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 15).

Figure 14. AC Voltmeter

Change-Over Switch

Figure 15. AC Voltmeter Gauge

(Volt reading on W-U Lug) dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 25

OUtpUt terMiNaL paNeL CONNeCtiONs uvWo Terminal ouTpuT volTages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the voltage change-over Board and the adjustment of the voltage regulator control Knob.

Remember the voltage change-over board determines the

range of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240v uvWo Terminal output voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 18

3. Turn the voltage regulator knob (Figure 20) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

Figure 20. Voltage Regulator Knob


1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18.

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

Figure 18. Voltage Change-Over Board 240V

Configuration


Figure 21. UVWO Terminal Lugs 1Ø-240V

Connections



2. Adjust voltage regulator knob (Figure 20) for an output of 208V to obtain 120V at the UVWO terminals.


Figure 19. UVWO Terminal Lugs


Connections page 26 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

OUtpUt terMiNaL paNeL CONNeCtiONs


1. Jumper the voltage change-over board for 480V operation as shown in Figure 23. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.




Figure 23. Voltage Change-Over Board 480V

Configuration



Connections





Connections

NOTICE

alWaYs make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a fire.


Connections dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 27

circuiT BreaKers

To protect the generator from an overload, a 3-pole, 600 amp, main circuit breaker is provided to protect the u,v,

and W output Terminals from overload. In addition two single-pole, 20 amp gFci circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp

load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch

all circuit breakers to 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 that the oil level is maintained between the two notches (Figure 27) on the dipstick. See Table 9 for proper selection of engine oil.

Figure 27. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the cummins engine owner’s manual. Oil should be warm before draining.

Delo® engine oil is the recommended engine oil for this generator. When replacing engine oil please refill using

Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil.

iNspeCtiON/setUp

Fuel checK

danger

Fuel spillage on a hot engine can cause a fire or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. never smoke around or near the generator.

refilling the Fuel system

cauTion

onlY properly trained personnel who have read and understand this section should refill the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 28). alWaYs fill the fuel tanks with clean fresh #2 diesel fuel. do noT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

Generator Internal Fuel Tank

Table 9. recommended motor oil

Trailer Fuel Tank

Figure 28. Internal Fuel Tank System page 28 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

refueling procedure:

Warning

diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

3. level Tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 29).

cauTion

alWaYs place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.


4. Open cabinet doors on the “right side” of the generator

(from generator control panel position). Remove fuel cap and fill tank (Figure 30).

Figure 30. Fueling the Generator

5. never overfill fuel tank — It is important to read the fuel gauge when filling trailer fuel tank. do noT wait for fuel to rise in filler neck (Figure 31).

300

Ground

=

DO NOT fill on unlevel ground

!

!

Ground

Figure 29. Only Fill on Level Ground

NOTICE

onlY use #2 diesel fuel when refueling.

Figure 31. Full Fuel Tank

cauTion

do noT overFill fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 32).

Figure 32. Fuel Expansion dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 29

coolanT (anTiFreeze/summer coolanT/

WaTer)

Cummins recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the

cummins engine owner’s manual for further details.

Warning

If adding coolant/antifreeze mix to the radiator, do noT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, do noT remove the radiator cap until the unit has completely cooled. See

Table 10 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

Table 10. coolant capacity

Engine and Radiator

Reserve Tank

11.4 gal (43 liters)

N/A

operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added.

Table 11. anti-Freeze operating Temperatures

Vol %

Anti-Freeze

Freezing Point

°C °F

50 -37 -34

iNspeCtiON/setUp cleaning the radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

air cleaner

Periodic cleaning/replacement is necessary. Inspect air cleaner in accordance with the cummins engine owner’s

manual.

Fan BelT Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the cummins engine owner’s manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 33) when depressed with the thumb as shown below.

Figure 33. Fan Belt Tension

cauTion

never place hands near the belts or fan while the generator set is running.

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.


BaTTerY

This unit is of negative ground do noT connect in reverse.

Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

do noT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. always keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery cable installation

ALWAYS be sure the battery cables (Figure 34) are properly connected to the battery terminals as shown below. The

red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

cauTion

alWaYs disconnect the negative terminal FirsT and reconnect negative terminal lasT.

Figure 34. Battery Connections


When connecting battery do the following:

1. never connect the battery cables to the battery terminals when the Auto-Off/Reset-Manual Switch is in either the auTo or manual position. alWaYs make sure that this switch is in the oFF/reseT position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

cauTion

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

alTernaTor

The polarity of the alternator is negative grounding type.

When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

do noT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

piping and hose connecTion

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( fuel or oil) lines are defective replace them immediately. dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 31

GeNeratOr start-Up prOCeDUre (MaNUaL)

BeFore sTarTing

cauTion

The engine’s exhaust contains harmful emissions.

alWaYs have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

sTarTing (manual)

1. Place the engine speed switch (Figure 37) in the LOW

(down) position.

Warning

never manually start the engine with the main, gFci

or auxiliary circuit breakers in the on (closed) position.

Figure 37. Engine Speed Switch (Low)

2. Place the Auto-Off/Reset Manual Switch in the

manual position to start the engine (Figure 38).

1. Place the main, g.F.c.i., and aux. circuit breakers

(Figure 35) in the oFF position prior to starting the engine.

Figure 38. Auto-Off/Reset Manua;Switch

(Manual Position)

NOTICE

If engine fails to start in a specified number attempts, the shutdown lamp will illuminate and the Auto-Off/

Reset Switch must be place inthe Off/Reset position before the engine can be restarted.

Figure 35. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been configured for the desired output voltage.

3. Connect the load to the receptacles or the output

terminal lugs as shown in Figure 10. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 36).

NOTICE

Engine will pre-heat automatically in cold weather conditions." Glow Plug Hold " message will be displayed and the engine will start automatically after pre-heating..

3. Once the engine starts, let the engine run for 1-2 minutes (let engine idle longer in cold weather conditions). Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem. If the engine is running smoothly, place the engine speed switch (Figure 39) in the high (up) position.

Figure 39. Engine Speed Switch (High)

4. The generator’s frequency meter (Figure 40) should be displaying the 60 cycle output frequency in herTz.

CORRECT INCORRECT

Figure 36. Engine Enclosure Doors

Figure 40. Frequency Meter page 32 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

GeNeratOr start-Up prOCeDUre (MaNUaL)

5. The generator’s AC-voltmeter (Figure 41) will display the generator’s output in volTs. If the voltage is not within the specified tolerance,

100

140

180

220

°F

260

WATER TEMP

Figure 41. Voltmeter

6. Use the voltage adjustment control knob (Figure 42) to increase or decrease the desired voltage.

Figure 42. Voltage Adjust Control Knob

7. The ammeter (Figure 43) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 45. Coolant Temperature Gauge

10. The tachometer gauge (Figure 46) will indicate the speed of the engine when the generator is operating.

Under normal operating conditions this speed is approximately 1800 RPM’s.

0

150

60

120

RPMX10

180

210

SPEED

Figure 46. Engine Tachometer Gauge

11. Place the main, gFci, and aux. circuit breakers in the

on position (Figure 47).

Figure 43. Ammeter (No Load)

8. The engine oil pressure gauge (Figure 44) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (193~586 kPa).

0

25

50

75

PSI

100

OIL PRESS

Figure 44. Oil Pressure Gauge

9. The coolant temperature gauge (Figure 45) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 180°~225°F (75°~95°C) ( green zone).


Circuit Breakers (ON)

12. Observe the generator’s ammeter (Figure 48) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 48. Ammeter (Load)

13. The generator will run until manually stopped or an abnormal condition occurs.


GeNeratOr start-Up prOCeDUre (aUtO MODe) sTarTing (auTo mode)

danger

Before connecting this generator to any building’s electrical system, a licensed

electrician must install an isolation

(transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

When starting generator in auTo mode use the “Manual

Start-up” procedure except where noted (see below).

1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure.

2. Place the engine speed switch (Figure 49) in the

high position

cauTion

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 battery.

NOTICE

When the generator is set in the auTo mode, the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

Warning

When running the generator in the auTo mode, remember the generator can start up at any time without warning. never attempt to perform any maintenance when the generator is in the auto mode.

cauTion

The engine speed switch must be set to the “High” position when running in the auto-start mode. Failing to set the switch in the proper position can result in damage to your generator when it turns on.

NOTICE

When the Auto Off/Reset Manual switch is placed in the auTo position, the engine glow plugs will be warmed and the engine will start automatically.

Figure 49. Engine Speed Switch (High)

3. Place the auto off/reset manual switch (Figure 50) in the auTo position.

Figure 50. auto off/reset manual Switch (AUTO)

4. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 5).


GeNeratOr shUt-DOWN prOCeDUres

Warning

never stop the engine suddenly except in an emergency.

normal shuTdoWn procedure

To shutdown the generator, use the following procedure:

1. Place both the main, gFci and load circuit breakers as shown in Figure 51 to the oFF position.

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

emergencY shuTdoWn procedure

1. To stop the engine in the event of an emergency, push the emergency stop button (Figure 54) inward. This button is located on the engine operating panel, see

Figure 5.


Circuit Breakers (OFF)

2. Place the engine speed switch (Figure 52) in the

“LOW” (down) position.

Figure 54. Emergency Stop Button

NOTICE

The emergency stop pushbutton switch is a push-lock type switch. The switch contacts will remain locked once the button has been pushed. To release the switch contacts rotate the button clockwise. The engine will not start unless the contacts are released.

Figure 52. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the auto off/reset manual switch (Figure 53) in the oFF/reseT position.

Figure 53. auto off/reset manual Switch

(Off/Reset)

5. Verify that all status LEDs on the ECU control panel are oFF (not lit). dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 35

MaiNteNaNCe

Table 12. inspection/maintenance

Check Engine Fluid Levels

Check Air Cleaner

Check Battery Acid Level

Check Fan Belt Condition

Check for Leaks engine

Check for Loosening of Parts

Replace Engine Oil and Filter * 1

Clean Air Filter

Check Fuel Filter/Water Separator Bowl

Clean Unit, Inside and Outside

Change Fuel Filter

Clean Radiator and Check Coolant Protection Level* 2

Replace Air Filter Element * 3

Check all Hoses and Clamps * 4

Clean Inside of Fuel Tank generator

Measure Insulation Resistance Over 3M ohms

Check Rotor Rear Support Bearing

* 1 Replace engine oil and filter at 100 hours, first time only.

10 hrs dailY

X

X

X

X

X

X

X

250 hrs 500 hrs

X

X

X

X

X

X

X

X

1000 hrs

X

X

* 2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

* 3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

* 4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot, with no sags or dips that could collect moisture and/or oil.

general inspecTion

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 12 as a general maintenance guideline engine side (Refer to the Engine

Instruction Manual)

air cleaner

Every 250 hours: Remove air cleaner element (Figure 55) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

air cleaner with dust indicator

This indicator () is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows red meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

NOTICE

Figure 55. Air Cleaner/Indicator

The air filter should not be changed until the indicator reads “red”. Dispose of old air filter. It may not be cleaned or reused..


If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

Fuel addiTion

Add diesel fuel (the grade may vary according to season and locations).

removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

cleaning inside the Fuel Tank

Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 56) wash out any deposits or debris that have accumulated inside the fuel tank.

MaiNteNaNCe

Fuel TanK inspecTion

In addition to cleaning the fuel tank, the following components should be inspected for wear:

rubber suspension — look for signs of wear or deformity due to contact with oil. Replace the rubber suspension if necessary.

Fuel hoses — inspect nylon and rubber hoses for signs of wear, deterioration and hardening.

Fuel Tank lining — inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter.

replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter.

Drain the fuel in the fuel body together with the mixed water. do noT spill the fuel during disassembly.

Vent any air

air removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the cummins

engine manual for details.

Figure 56. Fuel Tank Cleaning dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 37

To restart after running out of fuel, turn the switch to the

“ on” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

checK oil level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 27.

replacing oil Filter

Remove the old oil filter.

Apply a film of oil to the gasket on the new oil filter.

Install the new oil filter.

After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Flushing ouT radiaTor and replacing coolanT

Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

Check hoses for softening and kinks. Check clamps for signs of leakage.

Tighten both cocks and replace the overflow tank.

Replace with coolant as recommended by the engine manufacturer.

Close radiator cap tightly.

 Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. do

noT clean radiator core with any objects, such as a screwdriver.

Warning

Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

MaiNteNaNCe radiaTor cleaning

The radiator (Figure 57) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube.

When using a high pressure washer, stand at least 5 feet

(1.5 meters) away from the radiator to prevent damage to the fins and tube.

Figure 57. Radiator Cleaning

generaTor sTorage

For long term storage of the generator the following is recommended:

Drain the fuel tank completely. Treat with a fuel stabilizer if necessary.

Completely drain the oil from the crankcase and refill if necessary with fresh oil.

Clean the entire generator, internal and external.

Cover the generating set and store in a clean, dry place.

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires.


JacKeT WaTer heaTer and inTernal BaTTerY charger 120 vac inpuT recepTacles

(opTional)

This generator can be optionally equipped with two 120

VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger.

These receptacles 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 (See Table 6).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times.

To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

MaiNteNaNCe

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle

(not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size.

NOTICE

To ensure adequate starting capability, always have power applied to the generator's internal battery charger..

Figure 58. Battery Charger and Jacket Water

Heater Power Connections dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 39

emission conTrol

The emission control system employed with the Cummins

QSB&-G6 diesel engine consist of a Diesel Oxidation

Catalyst (DOC) and a Diesel Particulate Filter (DPF). The oxidation catalyst and particulate filter are housed in one unit. See Figure 61.

These devices help in filtering out large amounts of harmful

Nitrogen Oxides (NOx) and Particulate Matter (PM) which are emitted by diesel engines. These exhaust emissions pose serious environmental and health risks. It is important to maintain and service this DOC/DPF emission safety device on a periodic basis.

diesel oxidation catalyst (doc)

The DOC does not filter particles it oxidizes them. This catalyst (honeycomb like structure) uses a chemical process to break down pollutants in the exhaust stream into less harmful components. In general this catalyst collects/burns accumulated particulates. The DOC contains palladium and platinum which serve as a catalysts to oxidize hydrocarbons and carbon monoxide.

diesel particulate Filter (dpF)

A diesel particulate filter (DPF) is a device designed to remove diesel particulate matter (soot) from the exhaust gas of a diesel engine. This type of filter usually removes about 85-95% of the soot.

Soot accumulated in the DPF is removed via the

"regeneration process". Regeneration is the process of removing the accumulated soot from the filter. This regeneration process can occur in a few different ways.

passive regeneration — Occurs during normal operation, typically under heavy load applications. Soot is oxidized faster than it is collected.

active regeneration — Occurs when engine exhaust temperatures are not high enough to oxidize the soot collected in the DPF. Active regeneration requires assistance from the engine to help increase the heat level in the after-treatment system.

Active regeneration occurs at a normal engine speed of 1800 rpm. In addition active regeneration is initiated automatically by the Engine Control Module (ECM) timer based program every 96 hours. This timer base program will reset at the end of any regeneration mode.

ECU

MaiNteNaNCe

Forced (stationary) regeneration — A forced regeneration only occurs when the operator has initiated this action at the ECU and the ECM recognizes a preprogrammed set point of soot in the PDF to allow a forced regeneration cycle.

This process can take anywhere from 30 minutes to

1-1/2 hours. When forced regeneration is in process all loads must be removed from the generator, all circuit breakers must be placed in the OFF position (OPEN), and the engine speed set to idle.

dpF pre-alarm

In the event the Engine Control Unit (ECU) determines the soot level back pressure and/or tempertaure has reached a pre-determined trip point the ECU will indicate a maintenance action is required by the operator.

This maintenance action will be shown on the LCD display

(DPF Warning Symbol) and the AMBER pre-alarm LED on the ECU control panel will be ON (lit). See Figure 59.


DPF STAT

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

Engine Started

Shutdown

Pre-Alarm

Figure 59. ECU DPF Pre-Alarm

The DPF pre-alarm status symbol displayed in Figure 59 indicates the soot level buildup has exceeded a predetermined level and a "Forced Regeneration" action is required.

NOTICE

If the amBer pre-alarm warning LED is ever on, the operator should always take immediate action to correct the problem. If the engine is allow to run under this condition, a higher pressure differential will be created in the DPF and will result in the red status

LED being on, causing an engine shutdown.


ECU


DPF STAT

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

Figure 60. ECU DPF Engine Shutdown

NOTICE

If the red engine shutdown LED is ever on (Figure 60),

Cummins recommends that the DPF be removed, cleaned or replaced. In addition the shutdown code must be cleared. To clear the code, the ECM must be reset by a licensed Cummins Engine Service

Technician, using Cummins service software.

NOTICE

Soot and ash will accumulate in the DPF over time and must be cleaned. The ash is a result of the normal oil consumption while the engine is operated. The ash cleaning interval will largely depend on the engine's duty cycle and condition. Normal service intervals for cleaning ash from the DPF is every 6 months (5000 hours).

MaiNteNaNCe

Forced regeneraTion procedure

Follow the steps below to initiate a forced regeneration:

1. Verify that the amBer pre-alarm LED is on or

Flashing and the DPF symbol is shown on the

ECU display.

2. Place all circuit breakers in the oFF position.

3. Place the engine speed switch in the loW position.

4. Press the program/exit button on the ECU controller and select Force regen mode.

5. Press and hold the request until the regen acTive message is displayed on the screen, then release.

6. Once activated, regeneration will start automatically and the engine idling speed will increase through the forced regeneration cycle. This process will last anywhere from 30 minutes to 1-1/2 hours.

NOTICE

During the regeneration cycle the High

Exhaust System Temperature ( hesT) symbol may be displayed. Display of this symbol can be considered normal during the regeneration period.

ENGINE

EXHAUST (OUT)

DIESEL PARTICULATE

FILTER (DPF)

Figure 61. Typical DOC/DPF Unit

DIESEL OXIDATION

CATALYST (DOC)

ENGINE

EXHAUST (IN) dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 41

Trailer mainTenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the generator.

1. Fuel cell — Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking system — System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. gvWr — Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame length — Measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width — Measurement is from fender to fender

6. Jack stand — Trailer support device with maximum pound requirement from the tongue of the trailer.

7. coupler — Type of hitch used on the trailer for towing.

traiLer MaiNteNaNCe

8. Tire size — Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire ply — The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel hub — The wheel hub is connected to the trailer’s axle.

11. Tire rim — Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. lug nuts — Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 16 and Figure 62 for lug nut tightening and sequence.

13. axle — Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. suspension — Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. electrical — Electrical connectors (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.


BraKes

Trailer brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Figure 62 displays the major hydraulic surge brake components that will require inspection and maintenance.

Please inspect these components as required using steps

1 through 8 and Table 13 as listed below:

Brake adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

traiLer MaiNteNaNCe hydraulic surge Brakes

Hydraulic surge brakes (Figure 62) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 62. Hydraulic Brake Components

actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge

or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes.

As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

symptom

No Brakes

Table 13. hydraulic Brake Troubleshooting possible cause

Brake line broken or kinked?

Brake lining glazed?

solution

Repair or replace.

Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded?

Brake drums scored or grooved?

Tire pressure correct?

Tires unmatched on the same axle?

Brake components loose, bent or broken?

Brake drums out-of-round?

System lubricated?

Brake components correct?

Brake lining thickness incorrect or not adjusted correctly?

Enough brake fluid or correct fluid?

Correct weight.

Machine or replace.

Inflate all tires equally.

Match tires.

Replace components.

Replace.

Lubricate.

Replace and correct.

Install new shoes and linings.

Replace rubber parts fill with dot 4 fluid.


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

alWaYs wear safety glasses when removing or installing force fitted parts.

Failure to comply may result in serious injury.

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 and cause serious eye or bodily injury.

Tire Wear/inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation do

noT bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 14 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Wear pattern

Table 14. Tire Wear Troubleshooting cause

Center Wear Over inflation.

solution

Adjust pressure to particular load per tire manufacturer.

Edge Wear

Side Wear

Under inflation.

Loss of camber or overloading.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating.

Align wheels.

Toe Wear Incorrect toe-in.

Align wheels.

Cupping

Flat Spots

Out-of-balance.

Check bearing adjustment and balance tires.

Wheel lockup and tire skidding.

Avoid sudden stops when possible and adjust brakes.

traiLer MaiNteNaNCe suspension

The leaf suspension springs and associated components

(Figure 63) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components as detailed in Table 15.

Figure 63. Major Suspension Components

Table 15. suspension Torque requirements item Torque (Ft.-lbs.)

3/8" U-Bolt

7/16" U-Bolt

Min-30 Max-35

Min-45 Max-60

1/2" U-Bolt

Shackle Bolt

Spring Eye Bolt

Min-45 Max-60

Snug fit only. Parts must rotate freely.

Locking nuts or cotter pins are provided to retain nut-bolt assembly.

Shoulder Type

Min-30 Max-50

Shackle Bolt page 44 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

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 fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 64). do

noT torque the wheel lug nuts all the way down.

Tighten each lug nut in 3 separate passes as defined by Table 16.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

Wheel size

12"

Table 16. Tire Torque requirements

First pass

FT-lBs

20-25 second pass

FT-lBs

35-40

13" 20-25 35-40

14"

15"

16"

20-25

20-25

20-25

50-60

50-60

50-60

Third pass

FT-lBs

50-65

50-65

90-120

90-120

90-120

traiLer MaiNteNaNCe

Figure 64. Wheel Lug Nuts

Tightening Sequence

NOTICE

never use an pneumatic air gun to tighten wheel lug nuts.


traiLer WiriNG DiaGraM

Figure 66. Trailer/Towing Vehicle Wiring Diagram page 46 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

GeNeratOr WiriNG DiaGraM

Figure 67. Generator Wiring Diagram dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 47

eNGiNe WiriNG DiaGraM

Figure 68. Engine Wiring Diagram page 48 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

trOUBLeshOOtiNG (GeNeratOr)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant.

symptom

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Table 17. generator Troubleshooting possible problem

AC Voltmeter defective?

solution

Check output voltage using a voltmeter.

Is wiring connection loose?

Check wiring and repair.

Is AVR defective?

Replace if necessary.

Defective Rotating Rectifier?

Check and replace.

Defective Exciter Field?

Check for approximately 19 ohms across J & K on CN1

Is engine speed correct?

Turn engine throttle lever to “High”.

Is wiring connections loose?


Defective AVR?


Is wiring connections loose?


Defective AVR?

Short Circuit in load?


Check load and repair.

Over current?

Defective circuit breaker?

Confirm load requirements and reduce.

Check and replace.

Over current Relay actuated? Confirm load requirement and replace.


trOUBLeshOOtiNG DiaGNOstiCs

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself.

1. With the engine stopped ( oFF). Push and hold the

Hour Check Button (Figure 69) located on the control panel.

HOUR CHECK

BUTTON

5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode enables the ability to carry out the fault diagnostics as listed below:

dm1 active Faults — Displays active fault messages and codes.

dm2 messages and codes — Displays messages and codes which previously occurred that are recorded in the

Engine Control Module (ECM).

last shutdown — Displays the messages and codes that caused the most recent shutdown.

6. After perfoming diagnostic tests, place the Auto Off/

Reset Manual Switch in the oFF position

Figure 69. Hour Check Button

2. While keeping the Hour Check Button pressed, place the Auto Off/Reset Manual Switch (Figure 70) in the

manual position.

Figure 70. Auto-Off/Reset Switch

(Manual Position)

3. The Hour Check Menu Screen will be displayed on the ECU controller.

4. Releasing the Hour Check Button and pushing the

Program/Exit Button on the ECU controller will return the controller to the main screen.


NOtes


expLaNatiON Of CODe iN reMarks COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

sample parTs lisT

no. parT no. parT name qTY. remarKs

1 12345 BOLT .....................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

no. column

unique symbols — All items with same unique symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the

“Remarks” column.

duplicate item numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

parT no. column

numbers used — Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarifi ed in the “Remarks” Column.

qTY. column

numbers used — Item quantity can be indicated by a number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clarifi ed in the “Remarks”

Column.

remarKs column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

serial number Break — Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”

“S/N XXXX AND ABOVE”

“S/N XXXX TO S/N XXX”

specifi c model number use — Indicates that the part is used only with the specifi c model number or model number variant listed. It can also be used to show a part is NOT used on a specifi c model or model number variant.

Indicated by:

“XXXXX ONLY”

“NOT USED ON XXXX”

“make/obtain locally” — Indicates that the part can be purchased at any hardware shop or made 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 assembly/kit that can be purchased, or is not available for sale through Multiquip.


sUGGesteD spare parts dca220sscu/dca220sscu4i WhisperWaTT generaTor WiTh cummings qsB7-g6 diesel engine

1 To 3 uniTs

qty. p/n description

3............Y0602015150 .......HOSE, RADIATOR, HUMP

2............Y0602015151 .......HOSE, RADIATOR

2............Y0602015152 .......HOSE, RADIATOR

1............Y0602015153 ......HOSE, RADIATOR

3............Y0602015246 .......BELT, FAN

1............4921517 ................SENSOR, OIL PRESSURE

1............Y0602211320 .......SWITCH, COOLANT LEVEL

6............Y0602042578 .......FUEL FILTER CARTRIDGE

6............Y0602042579 .......CARTRIDGE WATER SEPERATOR

6............Y0602041296 .......FILTER, OIL CARTRIDGE

3............AF55014 ...............ELEMENT AIR CLEANER PRIMARY

3............AF55308 ...............ELEMENT AIR CLEANER SAFETY

1............0601808803 ..........CIRCUIT BREAKER 1P 20A

1............0601808804 ..........CIRCUIT BREAKER 2P 50A

2............LY2DUS24VDC ....RELAY

1............Y0601806603 .......FUSE, 150A

1............0601806671 ..........(LEFT) 15A

1............0601802131 ..........FUSE, (CENTER) 1A

1............0601802133 ..........FUSE, (RIGHT) 5A

1............Y0601806646 .......FUSE, 20A

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.


GeNeratOr assy.


no.

1

1-1#

1-2#

parT no.

C1110100302

0601842334

1-3#

1-4#

0601823282

0018205020

1-4A# 0032005000

1-4B# 0401450050

1-5#

1-6#

1-7#

1-8#

8171070002

8171611003

C1164200004

8171015003

1-9# 0012116045

1-10# 0042616000

5

6

3

4

7

7- 1

7- 2

7- 3

1-11# 0601000209

1-12# C1112500004

1-13# 0071906314

2 M3163400603

Y0343204200

EM923344

012112040

7- 4

7- 5

7- 6

7- 7

0042512000

C1130000103

0226100420

8171323004

0223300120

8171323103

0221200300

0010110035

7- 8

7- 9

031110160

C1132200003

0226000510

7- 10 0225000470

10

10A

10B

11

12

13

14

14A

14B

8

9

7- 11 0017106016

7- 12 0601850144

C1154000002

C1138000003

0012110065

0042610000

031110160

0017112045

C1154400004

C1154300004

0010106060

0040006000

952404470

GeNeratOr assy.

parT name qTY. remarKs

ROTOR ASS'Y .........................................1 ............. INCLUDES ITEMS W/#

FIELD ASS'Y

RESISTOR

RECTIFIER 1

HEX. SOCKET HEAD CAP SCREW 2

1

1

WASHER, LOCK

WASHER, FLAT

FAN

COUPLING DISK

1

9

2

2

WASHER, COUPLING HUB 1

BALANCING PLATE .................................1 ............. WHEN PURCHASING BALANCING

................................................................................ PLATE ITEM 1-11 MUST ALSO BE

................................................................................ ORDERED

HEX. HEAD BOLT

WASHER, LOCK

BALANCING WEIGHT KIT

BEARING FLANGE

BEARING

COUPING RING

HEX. HEAD BOLT

WASHER, LOCK

HEX. HEAD BOLT

WASHER, LOCK

STATOR ASS'Y

RUBBER SEAL

CLAMPER

RUBBER SEAL

CLAMPER

RUBBER SEAL

HEX. HEAD BOLT

WASHER, FLAT

COVER

RUBBER SEAL

RUBBER SEAL

HEX. HEAD BOLT

GROMMET

END BRACKET

FIELD ASS'Y, EXCITER

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX. HEAD BOLT

COVER, BEARING

GASKET, BEARING

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

8

8

1

1

1

1

8

8

8

8

1

1

1

1

1

1

2

2

1

2

1

6

1

1

1

4

4

4

6

1

1

4

4

4 dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 55

GeNeratOr assy. (CONtiNUeD)


no. parT no.

15 C1154400103

16 011106015

17 012112040

18 0042512000

18-1 031112230

19 C1132300114

20 0010006030

20A 952404470

20B 020106050

21 0605000012

22 0030020000

22A 030220510

23 M3163600103

24 012010030

25 030210250

26 M3163700004

27 0070506207

GeNeratOr assy. (CONtiNUeD)

parT name

SUCTION COVER

HEX. HEAD BOLT

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

COVER, FAN

HEX. HEAD BOLT

WASHER, FLAT

NUT

RUBBER SUSPENSION

HEX. NUT

WASHER, LOCK

COUPL ING ADAPTER

HEX. HEAD BOLT

WASHER, LOCK

SPACER, BEARING

BEARING

12

12

4

1

1

1

2

4

1

1

1

1

12

2

qTY.

1

8

12 remarKs dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 57

CONtrOL paNeL assy.


3

4

7

8

5

6

no.

1

parT no. parT name

M4223000503 CONTROL PANEL

2 M9220100004 SET SCREW

2A Y0080200007 E-RING

9

19

20

21

M4223000604 CONTROL PANEL

0017108040

0601840100

0601801040

0601801041

Y0602202642 ECU CONTROLLER

Y0602120569 GAUGE UNIT ASS'Y.

10 0601810171

11 0027104020

11A OEMAA8

12 0601831330

13 0601831205

14 82608

15 0601830710

16 0601831557

17 0601807642

18 0601808992

0601800275

0601840073

0605011211

HEX. HEAD BOLT

KNOB

CHANGE-OVER SWITCH, AMMETER

CHANGE-OVER SWITCH, VOLTMETER

PANEL LIGHT, 24V

MACHINE SCREW

HEX. NUT

PANEL LIGHT SWITCH

PUSH BUTTON

TOGGLE SWITCH

SWITCH, PANEL LIGHT

EMERGENCY STOP BUTTON

FEQUENCY METER, 45~65 HZ @240V

AC AMMETER, 0~400A/800A:5A

AC VOLTMETER, 0~600V

VOLTAGE REGULATOR, 1K OHM

PIN

22 M4246700604 WIRE HARNESS, GENERATOR

23 M4357200202 WIRE HARNESS, ENGINE

CONtrOL paNeL assy.

1

1

2

2

1

1

1

1

qTY.

1

2

2

1

1

1

4

1

1

1

1

1

1

1

1

1


CONtrOL BOx assy.


CONtrOL BOx assy.

no.

1

4

5

2

3

8

9

6

7


M4213000212 CONTROL BOX

011008020 HEX. HEAD BOLT

M4213400104 BACK PANEL

M4213500104 TOP PANEL


M4260500103 SET PANEL


Y0602201456 MAGNETIC SWITCH

Y0602201457 MAGNETIC SWITCH

10 0016906016 HEX. HEAD BOLT

RECTIFIER

1

16

1

4

qTY.

1

14

1 remarKs

11 0601821370

12 0027104020 MACHINE SCREW

1

1

4

2

2

13 LY2DUS24VDC RELAY ...............................................................1................REPLACES P/N 0601827655

13A PTF08A

13B PYCA1

14 0027104020 MACHINE SCREW

15 Y0601872130 HOLDER, FUSE

15A Y0601806603 FUSE,150A

16 0601815153

17 0027104020

18 0601802218

18A 0601806671

18B 0601802131

18C 0601802133

19 0027103020

20 0601809667

21 0027106020

RELAY BASE .....................................................1................REPLACES P/N 0601823109

RE LAY CLIP .....................................................1................REPLACES P/N 0601824400

TERMINAL BLOCK

MACHINE SCREW

HOLDER, FUSE

FUSE (LEFT), 15A

FUSE (CENTER), 1A

FUSE (RIGHT), 5A

MACHINE SCREW

CURRENT TRANSFORMER

MACHINE SCREW

22 Y0801820847 OVER CURRENT RELAY

23 0601820848

24 0027104020

OVER CURRENT RELAY

MACHINE SCREW

24A OEMAA8 HEX. NUT

25 Y0601807523 CIRCUIT BREAKER, 3P 600A

25-1 Y0601827412 REAR TERMINAL BUSBAR

26 014210040

26A

27

021112140

0601820604

HEX. HEAD BOLT

SELF-LOCKING NUT

AUTOMATIC VOLTAGE REGULATOR

1

1

2

1

2

1

1

1

1

2

3

6

1

1

2

2

1

2

6

6

1 dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 61

CONtrOL BOx assy. (CONtiNUeD)


CONtrOL BOx assy. (CONtiNUeD)


28 0027105016

30 011208030

parT name

MACHINE SCREW

29 M4273000003 TERM. BD, VOLTAGE CHANGE-OVER

31 8181852104

HEX. HEAD BOLT

CHANGE TERMINAL

32 Y0917106025 HEX. HEAD BOLT

33 8181853104 CHANGE-OVER PLATE

34 M4276200004 CHANGE PLATE

35 012210020

36 0041410000

TIE BOLT

WASHER, FLAT

WASHER, LOCK

HEX. HEAD BOLT

37 0040010000

38 014210040

38A 021112140 SELF-LOCKING NUT

39 Y0601808646 FUSE, 20A

40 M4213600104 STOPPER, CONTROL PANEL

41 952404470

42

43

44

505015300

0330000250

0027104020

WASHER, FLAT

SNAP PIN

EDGING

MACHINE SCREW

1

1

3

1

26

26

26

3

10

20

6

3

qTY.

4

1

4

1

1


eNGiNe aND raDiatOr assy.


no.

1


M4923200054 ENGINE, CUMMINS QSB7-G6

1A Y0602015246 FAN BELT

1-1 Y0602046648 ELEMENT, AIR CLEANER, INNER

1-1A Y0602046649 ELEMENT, AIR CLEANER, OUTER

1-2 RBX002252 AIR CLEANER INDICATER

1-3 Y0602041296 CARTRIDGE, OIL FILTER

1-4 Y0602042578 CARTRIDGE, FUEL FILTER

2

3

4

M4303200603 ENGINE FOOT

M4303200703 ENGINE FOOT

0131151240

4A 0040012000

7

8

5

6

HEX. HEAD BOLT

WASHER, LOCK

M4357300103 HARNESS CLAMP

Y0191701800 BLOWBY HOSE

0605515149 HOSE BAND

Y0602022588 ADAPTER

9 Y0602022579 90° ELBOW

10 Y0379500800 DRAIN HOSE

11 Y0603306399 HOSE JOINT

12 Y0605511399 VALVE

13 Y0603306597 CONNECTOR

14 Y0603300286 LOCKNUT

15 Y0602021071 CAP

16 Y0602012739 RADIATOR/CAC ASS'Y

17 Y0602011024 CAP, RADIATOR


18A 0043007000

18B 0043107000

20 0343206120

20A 030206150

20B 0043106000

21 0016310025

WASHER, LOCK

WASHER, FLAT

19 M4310201514 BRACKET

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX. HEAD BOLT

22 Y0602013263 TUBE, CAC HOT SIDE

23 Y0602014823 TUBE, CAC COLD SIDE

24 Y0602015150 HOSE, HUMP

24A Y0605515258 CLAMP, HOSE

25 Y0602014822 TUBE, WATER INLET

26 Y0602015151 HOSE, 70-175, L=5- 00"


27 Y0602326067 U-BOLT SET

28 Y0602013262 TUBE, WATER OUTLET

29 Y0602015152 HOSE, 70-175 L=5. 00"


30 Y0602015153 HOSE, 70-100 L=52"



eNGiNe aND raDiatOr assy.

2

2

2

2

2

2

1

2

1

1

1

1

1

1

1

1

2

1

1

1

6

6

1

1

1

1

1

1

qTY.

1

1

1

1

2

4

2

4

1

1

2

4

6

1

1

3

4


eNGiNe aND raDiatOr assy. (CONtiNUeD)


eNGiNe aND raDiatOr assy. (CONtiNUeD)

no. parT no. parT name

32 Y0602015154 HOSE, 70-038 1=18"

33 Y0602015155 HOSE, 70-038 L=29.5"

34 Y0602015156 HOSE, 70-038 L=43. 5"

35 0605515198 HOSE BAND

36 Y0603307520 45° ELBOW

37 Y0605511394 VALVE


39 0193600400 DRAIN HOSE

40 Y0199101900 OVER FLOW HOSE

41 0605515170 HOSE BAND

42 Y0602211320 COOLANT LEVEL SWITCH

43 Y0605000010 RUBBER SUSPENSION

43A 0030012000

43B 0040012000

HEX. NUT

WASHER, LOCK

44 M3483600104 CLAMP

2

1

2

2

2

1

1

1

1

1

6

1

qTY.

1

1


OUtpUt terMiNaL assy.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN

6-CATERPILLAR YELLOW

7-CATO GOLD

8-RED

9-DESERT TAN

5-BLACK

THE SERIAL NUMBER MAY BE REQUIRED.


6

7

8

9

2

3

4

5

no.

1


C1231700003 TERMINAL BOARD

M9220100304 OUTPUT TERMINAL BOLT

0801830804 TIE BOLT

TERMINAL PLATE 3461860504

0039316000

0040016000

0401450160

HEX. NUT

WASHER, LOCK

WASHER, FLAT

HEX. HEAD BOLT 0016908040

M4236100403 TERMINAL COVER

10 0016906016

11 0605010040

12 0027103010

12A 0207003000

12B 0041203000

13 0027103015

HEX. HEAD BOLT

HINGE

MACHINE SCREW

HEX. NUT

WASHER, FLAT

MACHINE SCREW

13A 0207003000 HEX. NUT

14 M4236100504 OUTPUT WINDOW

15 M9220100804 SET SCREW

16 0040006000

17 952404470

18 0080200005

WASHER, LOCK

WASHER, FLAT

RING

19 M4236100703 TERMINAL COVER

20 0805009804

21 012212045

22 031112230

23 0030012000

STAY RUBBER

HEX. HEAD BOLT

WASHER, FLAT

HEX. NUT

24 0605011505

25 0027105016

STAY

MACHINE SCREW

26 M4236400204 COVER

27 0016906016 HEX. HEAD BOLT

28 M4260600104 BRACKET, CIRCUIT BREAKER

28-1 0222100150

29 011206020

30 0601808803

31 0601808804

33 0601814013

RUBBER CUSHION

HEX. HEAD BOLT

CIRCUIT BREAKER, 1P, 20A

CIRCUIT BREAKER, 2P, 50A

32 Y0601814014 RECEPTACLE, CS-6369L, 50A

RECEPTACLE, GF-20LA, 20A

MACHINE SCREW

HEX. NUT

GROMMET

34 7538070

34A OEMAA8

35 0601850275

36 0601815194

37

38

39

40

7538070

0603306775

7538070

0017110025

TERMINAL BLOCK

MACHINE SCREW

BLIND PLUG

MACHINE SCREW

40A 0040510000

HEX. HEAD BOLT

TOOTHED WASHER

41 M4236100604 INSULATING COVER

42 M4236400304 BRACKET

43 0016906016 HEX. HEAD BOLT

44 M4236400004 CABLE OUTLET COVER

45 M4236400104 SUPPORTER, CABLE OUTLET COVER

46 011206020 HEX. HEAD BOLT

OUtpUt terMiNaL assy.

8

1

4

1

2

1

2

4

1

2

2

2

2

2

4

1

4

4

4

4

4

2

5

1

qTY.

1

8

8

3

16

24

32

1

1

4

1

2

2

1

I

1

1

1

2

8

3

2

10

10

2

3

1


Battery assy.


Battery assy.

7

8

5

6


1

2

3

0602220199

M9103000804

3A#

0602220920

parT name

BATTERY

BATTERY BAND

qTY.

2 remarKs

1

BATTERY BOLT SET .........................................2 ...............INCLUDES ITEMS W/#

3B#

4

WING NUT

PLASTIC WASHER

M9310500014 BATTERY SHEET

M4346900404 BATTERY CABLE

9



020108060

0040508000

10 0016910025

11 0040510000

12

HEX. NUT

TOOTHED WASHER

HEX. HEAD BOLT

TOOTHED WASHER

2

1

2

2

1

1

1

1

1

1

EARTH CABLE ..................................................1................MAKE LOCALLY dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 71

MUffLer assy.


4

5

2

3

6

7

no.

1


Y0602300240 DEVICE, AFTER TREATMENT

8

M4330400003

0016910025

BRACKET

HEX. HEAD BOLT

M2330400704 BAND

011008020

0207308000

M4333000503

Y0602325039

HEX. HEAD BOLT

SUPER LOCK NUT

EXHAUST PIPE

V-BAND CLAMP

8A Y0602320129 GASKET

9 Y0602325038 V-BAND CLAMP

9A Y0602320128 GASKET

10 M3330400804 EXHAUST PIPE COVER

11 M3330400903 EXHAUST PIPE BRACKET

12 011008020

13 0602326062

HEX. HEAD BOLT

U-BOLT SET

14 M4333100004 EXHAUST TAIL PIPE

15 M4357300014 HARNESS CLAMP

16 011008020

17 0601851736

18 Y0602311130 EXHAUST INSULATING WRAP

19 0605515225

20 0602220911

21 0016910025

HEX. HEAD BOLT

GROMMET

HOSE BAND

CLAMP

HEX. HEAD BOLT

4

1

1

1

1

1

1

1

2

1

2

2

qTY.

1

1

4

1

1

1

4

2

1

1

1

MUffLer assy.

remarKs dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 73

fUeL taNk assy.


5

6

3

4

7

8

no.

1


M4363000202 FUEL TANK

1-1

2

0605505070 FUEL TANK CAP

M4363200004 TANK BAND

9

M9310500104

011008020

0207308000

0191302300

0605515109

Y0602042579

10 014210040

SUPPORTER SHEET

HEX. HEAD BOLT

SUPER LOCK NUT

SUCTION HOSE

Y0191204000 RETURN HOSE

HOSE BAND

CART., FUEL WATER SEPARATOR

HEX. HEAD BOLT

11 Y0602022578 90° ELBOW


13 0602220911

13A 0016906016

CLAMP

HEX. HEAD BOLT

14 M1363400104 DRAIN HOSE

15 0605515198 HOSE BAND

16 1502025103C DRAIN JOINT

17 011206020

18 0802011104

18A 0150000018

HEX. HEAD BOLT

DRAIN BOLT

O-RING

1

1

1

1

1

2

1

4

2

1

4

2

qTY.

1

1

2

1

2

1

2

1

1

fUeL taNk assy.

remarKs dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 75

eNCLOsUre assy.


2

3

no.

1


M4413000412 BASE

4

M1413400004

011008020

COVER

HEX. HEAD BOLT

M4423000512 FRONT FRAME

4A M4493104603 ACOUSTIC SHEET

6

7

5 M4423000602 FRONT FRAME


011008020

0016910025

HEX. HEAD BOLT

HEX. HEAD BOLT

8 M4423200004 COVER, FRONT FRAME


9 0019208020 HEX. HEAD BOLT

10 M4423200503 TOP COVER, FRONT FRAME

11 0019208020 HEX. HEAD BOLT

12 M4433000212 CENTER FRAME

13

13A

13B

13C

14

14A

14B

14C

0010114040

030214350

031114260

515455840

0010120050

030220510

0041220000

0030020000

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX. NUT

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

HEX. NUT

15 M4443000202 REAR FRAME


16 0016910025 HEX. HEAD BOLT

17 M4443300404 COVER, REAR FRAME


18 0019208020 HEX. HEAD BOLT

19 M4443300503 DUCT, REAR FRAME


20 020108060 HEX. NUT

21 M4443200403 DOOR, REAR FRAME

22 M9110100204 HINGE

22A M9116100004 WASHER

23 0845031504 BLIND PLUG




1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN


7-CATO GOLD

8-RED

9-DESERT TAN

5-BLACK



1

1

1

14

4

1

1

1

2

2

9

1

2

8

4

4

4

8

4

4

4

22

1

15

1

10

10

1

1

1

1

1

I

qTY.

1

1

2

eNCLOsUre assy.

remarKs

eNCLOsUre assy. (CONt.)



24 0019208020

25 0601850097

26 0027208025

parT name

HEX. HEAD BOLT

STOPPER

MACHINE SCREW

27 M4443600004 WINDOW PLATE

28 020106050 SELF-LOCKING J NUT

WASHER, FLAT 28A 952404470

29 0600800320

30 0021806016

MANUAL PACK

MACHINE SCREW

31 M9114000002 DOOR HANDLE

32 0021806016

32A 020106050

MACHINE SCREW

HEX. NUT

33 M4463100302 ROOF PANEL


34 0019208020 HEX. HEAD BOLT

35 M3310600004 COVER

36 0019208020 HEX. HEAD BOLT

37 M4463200502 ROOF PANEL


38 0019208020 HEX. HEAD BOLT

HEX. HEAD BOLT 39 0017110025

40 M4463200304 COVER


42 M4463200603 DUCT, REAR ROOF


43 0016908020 HEX. HEAD BOLT

44 M4463500204 GUTTER

45 0019206015 HEX. HEAD BOLT

46 M4453200202 SPLASHER PANEL


47 0019108065

47A 0042308000

47B 031108160

HEX. HEAD BOLT

WASHER, LOCK

WASHER, FLAT

48 M4453001403 SIDE DOOR


49 M4453001503 SIDE DOOR



6

6

1

1

2

8

1

10

1

1

6

1

1

12

1

4

2

1

16

4

1

10

1

1

1

4

4

4

1

8

1

1

8

qTY.

3

1

1 remarKs




1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN


7-CATO GOLD

8-RED

9-DESERT TAN

5-BLACK





no. parT no. parT name

50 M4453001603 SIDE DOOR


51 M4453001703 SIDE DOOR


52 M4453301104 DUCT


53 M4453301204 DUCT


54 M4453301304 DUCT


55 M4453301404 DUCT


56 020108060 HEX. NUT



59 0021806018

59A 020106050

MACHINE SCREW

HEX. NUT

60 M4453600004 GUTTER

61 M4453600104 GUTTER

62 0019206015

63 0845046904

HEX. HEAD BOLT

HINGE

63A M9116100004 WASHER

64 0845047004 HINGE

64A M9116100004 WASHER .

65 0019208020

66 0601850097

67 0027208025

68 0845031504

HEX. HEAD BOLT

STOPPER

MACHINE. SCREW

BLIND PLUG


5

6

18

5

3

3

28

28

8

8

6

25

11

4

3

1

36

1

1

1

1

3

1

1

3

qTY.

1

1

1 remarKs




1-ORANGE

2-WHITE

3-SPECTRUM GREY

4-SUNBELT GREEN


7-CATO GOLD

8-RED

9-DESERT TAN

5-BLACK



rUBBer seaLs assy.



13

14

15

16

9

10

11

12

5

6

7

8

1

2

3

4

0229201300

0229201200

0228901120

0228901260

0228900660

0228900795

0228901055

0228901200

0228900600

0229400630

0228801050

0228800590

0228100560

0228100370

0222100120

0222100180

parT name

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

SEAL RUBBER

RUBBER SHEET

RUBBER SHEET

rUBBer seaLs assy.

qTY.

2

2

2

2

2

1

1

1

4

3

1

4

1

3

4


NaMepLate aND DeCaLs assy.


NaMepLate aND DeCaLs assy.

no. parT no. parT name qTY. remarKs

1-1 M4550000603 DECAL: OPERATING PROCEDURES .............1 ................M45000060

1-2 M4550000703 DECAL: DPF REGEN. PROCEDURES ............1 ................M45000070

1-3 M9520100304 DECAL: SAFETY INSTRUCTIONS ..................1 ................M92010030

1-4 M9520100603 DECAL: CAUTION ............................................2 ................M92010060

conTrol panel and Box group ...............................

2-1 M4550000402 DECAL: CONTROL PANEL ..............................1 ................M4S000040

2-2 M9520000104 PLATE: AMMETER CHANGE-OVER SW. ........1 ................M92000010

2-3 M9520000204 PLATE: VOLTMETER CHANGE-OVER SW. .....1 ................M92000020

2-4 M9520100004 DECAL: WARNING, ELECT. SHOCK HAZ. ......2 ................M92010000

2-5 M9520100704 DECAL: WARNING, ARC FLASH .....................1 ................M92010070

2-6 M9520200404 DECAL; OVER CURRENT RELAY ...................1 ................M92020040

2-7 M9522000504 DECAL: CIRCUIT BREAKER ...........................1 ................M92200050

2-8 M9520200303 DECAL: SET FOR OUTPUT VOLTAGE ............1 ................M92020030

2-9 M9520200504 DECAL: SET FOR OUTPUT VOLTAGE (S) .....1 ................M92020050

engine and radiaTor group ...................

3-1 M9500000004 DECAL: 0IL DRAIN PLUG ................................1 ................M90000000

3-2 M9500100004 DECAL: WATER ................................................1 ................M90010000

3-3 M9503000004 DECAL: WARNING, ROTATING PART .............2 ................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

mounT Terminal group ............................

4-1 M4550000503 DECAL: RECEPT. AND CB ...............................1 ................M45000050

4-2 M9520000004 DECAL: GROUND ............................................2 ................M92000000

4-3 M9520000504 DECAL: START CONTACT .............................1 ................M92000050

4-4 M9520000704 DECAL: 3-PHASE OUTPUT TERMINAL ..........1 ................M92000070

4-5 M9520100404 DECAL: DANGER, HIGH VOLTAGE .................1 ................M92010040

4-6 M9520100503 DECAL: WARNING ...........................................1 ................M92010050

BaTTerY group ............................................

5-1 M9500300004 DECAL: - ...........................................................1 ................M90030000

5-2 M9500300104 DECAL:+ ...........................................................1 ................M90030010

5-3 M9510100403 DECAL: CAUTION ............................................1 ................M91010040

MUFFLER GROUP ..............................................................

6-1 M9503200004 DECAL: WARNING, ENGINE EXHAUST .........1 ................M90320000

6-2 M9503200104 DECAL: DANGER, EXHAUST ..........................1 ................M90320010

6-3 M9504200004 DECAL: WARNING, START FIRES ..................1 ................M90420000

FUEL TANK GROUP ..........................................

7-1 M9501500004 DECAL: DIESEL FUEL .....................................2 ................M90150000

7-2 M9500500104 DECAL: FUEL DRAIN PLUG ............................1 ................M90050010


NaMepLate aND DeCaLs assy. (CONt.)


NaMepLate aND DeCaLs assy. (CONt.)

no. parT no. parT name enclosure group

qTY. remarKs

8-1 M9510200002 DECAL: MQ .......................................................1................M91020000

8-2 0600500090

8-2A 0021106016

EMBLEM

MACHINE SCREW

2

4

8-3 M4560100704 STRIPE ..............................................................2................M46010070

8-4 M4560101404 STRIPE ..............................................................1................M46010140

8-5 M4560101504 STRIPE ..............................................................2................M46010150

8-6 M4560101603 STRIPE ..............................................................2................M46010160

8-7 M4560100003 STRIPE ..............................................................1................M46010000

8-8 M4560101703 STRIPE ..............................................................1................M46010170

8-9 M3550002204 DECAL: CAUTION .............................................1................M35000220

8-10 M9512000004 DECAL: SUPPORT HOOK ..........................2................M91200000

8-11 M9510000104 DECAL: DOCUMENT BOX LOCATED ..............1................M91000010


terMs aND CONDitiONs Of saLe — parts

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1.

2.

3.

4.

A Returned Material Authorization must be approved by Multiquip prior to shipment.

To obtain a Return Material Authorization, a list must be provided to Multiquip

Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions must match the current parts price list.

b. The list must be typed or computer generated.

c. d.

The list must state the reason(s) for the return.

The list must reference the sales order(s) or invoice (s) under which the items were originally purchased.

e. The list must include the name and phone number of the person requesting the RMA.

A copy of the Return Material Authorization must accompany the return shipment.

Freight is at the sender’s expense. All parts must be returned freight prepaid to

Multiquip’s designated receiving point.

5.

6.

7.

8.

9.

10.

11. d. e. f. g. h.

Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

The following items are not returnable: a. b.

Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.)

Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer net price of less than

$5.00.

Special order items.

Electrical components.

Paint, chemicals, and lubricants.

Decals and paper products.

Items purchased in kits.

The sender will be notified of any material received that is not acceptable.

Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge.

In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price.

Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to

Original Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

Effective: February 22, 2006 page 88 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12)

NOtes


OperatiON MaNUaL

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Office

18910 Wilmington Ave.

Carson, CA 90746

Contact: [email protected]

Service Department

800-421-1244

310-537-3700

Technical Assistance

800-478-1244

Tel. (800) 421-1244

Fax (310) 537-3927

Fax: 310-537-4259

Fax: 310-943-2238 mexico

MQ Cipsa

Carr. Fed. Mexico-Puebla KM 126.5

Momoxpan, Cholula, Puebla 72760 Mexico


Tel: (52) 222-225-9900

Fax: (52) 222-285-0420

MQ Parts Department

800-427-1244

310-537-3700

Warranty Department

800-421-1244

310-537-3700

Fax: 800-672-7877

Fax: 310-637-3284

Fax: 310-943-2249

United Kingdom

Multiquip (UK) Limited Head Office

Unit 2, Northpoint Industrial Estate,

Globe Lane,

Dukinfield, Cheshire SK16 4UJ


Tel: 0161 339 2223

Fax: 0161 339 3226

Canada

Multiquip

4110 Industriel Boul.

Laval, Quebec, Canada H7L 6V3


Tel: (450) 625-2244

Tel: (877) 963-4411

Fax: (450) 625-8664

© COPYRIGHT 2012, MULTIQUIP INC.

Multiquip Inc, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual MUsT accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

Multiquip DCA220SSCU4i Operation And Parts Manual

OperatiON aND parts MaNUaL

WhisperWatt™ series

60hz GeNeratOr

(CUMMiNs QsB7-G6 DieseL eNGiNe)

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

prOpOsitiON 65 WarNiNG

Diesel engine exhaust and some of

repOrtiNG safety DefeCts

taBLe Of CONteNts

Component Drawings

NOtes

saFeTY messages

safety iNfOrMatiON

general saFeTY

safety iNfOrMatiON

generaTor saFeTY

engine saFeTY

safety iNfOrMatiON

Fuel saFeTY

ToWing saFeTY

safety iNfOrMatiON

elecTrical saFeTY

power cord/cable safety

safety iNfOrMatiON

grounding safety

BaTTerY saFeTY

safety iNfOrMatiON environmenTal saFeTY

speCifiCatiONs

DiMeNsiONs

iNstaLLatiON

ouTdoor insTallaTion

indoor insTallaTion

mounTing

iNstaLLatiON generaTor grounding

generaTor

operaTing panel

conTrol panel

ouTpuT Terminal panel

GeNeraL iNfOrMatiON open delTa exciTaTion sYsTem

engine

elecTric governor sYsTem

exTension caBles

MajOr COMpONeNts

eNGiNe CONtrOL UNit (eCU)

eNGiNe/GeNeratOr CONtrOL paNeL

OUtpUt terMiNaL paNeL faMiLiariZatiON ouTpuT Terminal panel

ouTpuT Terminal FamiliarizaTion

OUtpUt terMiNaL paNeL faMiLiariZatiON

120 vac gFci receptacles

Twist lock dual voltage 120/240 vac receptacles

OUtpUt terMiNaL paNeL faMiLiariZatiON connecting loads

over current relay

single phase load

LOaD appLiCatiON

Three phase load

generaTor ouTpuT volTages

voltage change-over Board

GeNeratOr OUtpUts maximum amps

GeNeratOr OUtpUts/GaUGe reaDiNG hoW To read The ac ammeTer and ac volTage gauges

ac ammeter gauge reading

ac voltmeter gauge reading

OUtpUt terMiNaL paNeL CONNeCtiONs uvWo Terminal ouTpuT volTages

3Ø-240v uvWo Terminal output voltages

1Ø-240v uvWo Terminal output voltages

1Ø-120v uvWo Terminal output voltages

OUtpUt terMiNaL paNeL CONNeCtiONs

3Ø-480v uvWo Terminal output voltages

1Ø-480v uvWo Terminal output voltages

1Ø-277v uvWo Terminal output voltages

circuiT BreaKers

luBricaTion oil

iNspeCtiON/setUp

Fuel checK

refilling the Fuel system

refueling procedure:

iNspeCtiON/setUp

coolanT (anTiFreeze/summer coolanT/

WaTer)

operation in Freezing Weather