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Multiquip DCA220SSCU4i User's Manual

1. 46 Generator Wiring Diagram 47 Engine Wiring 48 Troubleshooting Generator 49 Troubleshooting Diagnostics 50 Explanation of Code in Remarks Column 52 Suggested Spare Parts 53 TABLE OF CONTENTS Component Drawings Generator 54 57 Control Panel Assembly 58 59 Control Box Assembly 60 63 Engine And Radiator Assembly 64 65 Output Terminal Assembly 66 67 Battery ASSeITIDIV 68 69 Muffler Assembly 70 71 Fuel Tank 58569 io panis 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 PAGE 4 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NOTES DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 5 SAFETY
2. ELEMENT AIR CLEANER SAFETY 0601808803 CIRCUIT BREAKER 1P 20A Rum 0601808804 CIRCUIT BREAKER 2P 50A LY2DUS24VDC RELAY Y0601806603 FUSE 150A doses 0601806671 LEFT 15A 0601802131 FUSE CENTER 1A 0601802133 FUSE RIGHT 5A 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 53 GENERATOR ASSY PAGE 54 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 1 13 PART NO C1110100302 0601842334 0601823282 0018205020 0032005000 0401450050 8171070002 8171611003 C1164200004 8171015003 0012116045 0042616000 0601000209 C1112500004 0071906314 M3163400603 Y0343204200 EM923344 012112040 0042512000 C1130000103 0226100420 8171323004 0223300120 8171323103 0221200300 0010110035 031110160 C1132200003 0226000510 0225000470 0017106016 0601850144 C1154000002 C1138000003 0012110065 0042610000 031110160 0017112045 C1154400004 C1154300004 0010106060 0040006000 952404470 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 55 PART NAME ROTOR 5 FIELD ASS Y RESISTOR RECTIFIER
3. DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 32 0602015154 33 0602015155 34 0602015156 35 0605515198 36 0603307520 37 0605511394 38 0605512192 39 0193600400 40 0199101900 41 0605515170 42 0602211320 43 0605000010 43A 0030012000 43B 0040012000 44 M3483600104 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 67 ENGINE AND RADIATOR ASSY CONTINUED PART NAME HOSE 70 038 1 18 HOSE 70 038 L 29 5 HOSE 70 038 L 43 5 HOSE BAND 45 ELBOW VALVE HOSE JOINT DRAIN HOSE OVER FLOW HOSE HOSE BAND COOLANT LEVEL SWITCH RUBBER SUSPENSION HEX NUT WASHER LOCK CLAMP QTY REMARKS ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8 RED 4 SUNBELT GREEN 9 DESERT TAN 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED OUTPUT TERMINAL ASSY PAGE 68 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 C1231700003 2 M9220100304 3 0801830804 4 3461860504 5 0039316000 6 0040016000 7 0401450160 8 0016908040 9 M4236100403 10 0016906016 11 0605010040 12 0027103010 12A 0207003000 12B 0041203000 13 0027103015 13A 0207003000 14 4236100504 15 9220100804 16 0040006000 17 952404470 18 0080
4. dessen M91020000 8 29 0600500090 EMBLEM 2 8 2A 0021106016 MACHINE SCREW 4 8 3 M4560100704 STRIPE a M di iR S 46010070 8 4 4560101404 STRIPE 46010140 8 5 4560101504 2 46010150 8 6 4560101603 46010160 8 7 4560100003 Tirnama M46010000 8 8 M4560101703 STRIPE 46010170 8 9 M3550002204 DECAL CAUTION 17 1 M35000220 8 10 4 DECAL SUPPORT HOOK 91200000 8 11 M9510000104 DECAL DOCUMENT BOX LOCATED M91000010 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 87 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 prov
5. BATTERY ASSY PAGE 70 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 0602220199 2 M9103000804 3 0602220920 3B 4 M9310500014 5 M4346900404 6 M3346902104 7 M4346900504 8 020108060 9 0040508000 10 0016910025 11 0040510000 12 BATTERY ASSY PART NAME QTY REMARKS BATTERY BATTERY BAND BATTERY BOLT 9 WING NUT PLASTIC WASHER BATTERY SHEET BATTERY CABLE BATTERY CABLE BATTERY CABLE HEX NUT TOOTHED WASHER HEX HEAD BOLT TOOTHED WASHER EARTH CABLE u T 2 1 2 2 2 2 1 1 1 1 1 1 1 1 MM SE INCLUDES ITEMS W md MAKE LOCALLY DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 71 MUFFLER ASSY PAGE 72 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 0602300240 2 M4330400003 3 0016910025 4 2330400704 5 011008020 6 0207308000 7 4333000503 8 0602325039 8A Y0602320129 9 0602325038 9 0602320128 10 3330400804 11 3330400903 12 011008020 13 0602326062 14 4333100004 15 4357300014 16 011008020 17 0601851736 18 0602311130 19 0605515225 20 0602220911 21 0016910025 PART DEVICE AFTER TREATMENT BRACKET HEX HEAD BOLT BAND HEX HEAD BOLT SUPER LOCK NUT EXHAUST PIPE V BAND CLAMP GASKET V BAND CLAMP GASKET EXHAUST PIPE COVER EXHAUST PIPE BR
6. DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 DIMENSIONS TOP VIEW i 14 050 Ibs 6 373 kg Figure 1 Dimensions Table 3 Dimensions iris Dimension in mm Reference Letter Dimension in mm F 159m 650m H srin 4 900 mn DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 13 INSTALLATION E GENERATOR GROUND LUG GROUND ROD 1 FOR EARTH GROUND 3 ED CONNECT TO BUILDING gt GROUND GROUND CABLE 8 FT MINIMUM REFERENCE NEC250 834C Figure 2 Typical Generator Grounding Application PAGE 14 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 INSTALLATION 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
7. DECAL WARNING HOT COOLANT 90310000 DECAL CAUTION HOT PARTS lupos M91010000 MOUNT TERMINAL GROUP DECAL RECEPT AND 45000050 DECAL GROUND 92000000 DECAL START CONTACT eee M92000050 DECAL 3 PHASE OUTPUT TERMINAL m M92000070 DECAL DANGER HIGH VOLTAGE Teria M92010040 DECAL WARNING enn 92010050 BATTERY GROUP 90030000 DECAL dd aa kama M90030010 91010040 MUFFLER GROUP on cda pt DECAL WARNING ENGINE EXHAUST M90320000 DECAL DANGER EXHAUST M90320010 DECAL WARNING START FIRES 90420000 FUEL TANK GROUPS DECAL DIESEL FUEL 90150000 DECAL FUEL DRAIN 1 90050010 NAMEPLATE AND DECALS ASSY CONT PAGE 86 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NAMEPLATE AND DECALS ASSY CONT NO PART PART NAME QTY REMARKS ENCLOSURE GROUP 8 1 9510200002 DECAL
8. 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 REMARKS QTY 1 CONTROL PANEL ASSY E7 x PAGE 58 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 4223000503 2 9220100004 2 0080200007 3 4223000604 4 0017108040 5 0601840100 6 0601801040 7 0601801041 8 0602202642 9 0602120569 10 0601810171 11 0027104020 11 _ 8 12 0601831330 13 0601831205 14 82608 15 0601830710 16 0601831557 17 0601807642 18 0601808992 19 0601800275 20 0601840073 21 0605011211 22 M4246700604 23 M4357200202 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 59 PART NAME CONTROL PANEL SET SCREW E RING CONTROL PANEL HEX HEAD BOLT KNOB CHANGE OVER SWITCH AMMETER CHANGE OVER SWITCH VOLTMETER ECU CONTROLLER GAUGE UNIT ASS Y 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 AMMETER 0 400A 800A 5A AC VOLTMETER 0 600V VOLTAGE REGULATOR 1K OHM PIN WIRE HARNESS GENERATOR WIRE HARNESS ENGINE CONTROL PANEL ASSY QTY Ps sss s REMARKS CONTROL BOX ASSY PAGE 60 DCA220SSCU 4i 60
9. 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 Anchor Post Backing Plate Hold Down Spring Adjuster Spring Adiuster Assembly 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 Table 13 Hydraulic Brake Troubleshooting f Brake components bent or Replace components Locking Brakes broken Brake drums out of round System lubricated Noisy Brakes Brake components correct Replace and correct Brake lining thickness incorrect or Install new shoes and not adjusted correctly linings Replace rubber parts Enough brake fl t fluid nough brake fluid or correct fluid fill with dot 4 fluid Dragging Brakes DCA220SSCU 4i 60 HZ GENERA
10. 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 trailers 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 SAFETY INFORMATION ELECTRICAL SAFETY DO NOT touch output terminals during operation Contact with output terminals during operation can cause electrocution electrical shock or burn 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 e receptacles during operation This is N 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 caus
11. immediately Generator Internal Fuel Tank P3 285 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 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 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 DO NOT fill on unlevel ground Y Figure 29 Only Fill on Level Ground NOTICE ONLY use 2 diesel fuel when refueling INSPECTION SETUP 4 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank Figure 30 WHISPERWATT DIESEL I xx L FUEL _ Figure 30 Fueling the Generator FUEL TANK FILLER PORT 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 FUEL GAUGE LOCATED ON CONTROL PANEL 4 A OL A OL OM th OL Of Oh 0h th th th tf eh fel gll tl 0 Figure 31
12. in the AUTO position domm AUTO ce MANUAL OFF RESET 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 PAGE 34 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 GENERATOR SHUT DOWN PROCEDURES NEVER stop the engine suddenly except in an emergency NORMAL SHUTDOWN PROCEDURE To shutdown the generator use the following procedure 1 2 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 51 to the OFF position MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 51 Main Aux Circuit Breakers OFF Place the Engine Speed Switch Figure 52 in the LOW down position Q LOW DOWN Figure 52 Engine Speed Switch Low Let the engine cool by running it at low speed for 3 5 minutes with no load applied Place the Auto Off Reset Manual Switch Figure 53 in the OFF RESET position AUTO x MANUAL OFF RESET Figure 53 Auto Off Reset Manual Switch Off Reset Verify that all status LEDs on the ECU control panel are OFF not lit 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 emer
13. 0 10 25 12 SAFETY INFORMATION GENERAL SAFETY 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 operate this equipment when not feeling well due to fatigue illness or when under medication NEVER operate this equipment under the influence 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 qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties NEVER use accessories or attachments that 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 fire extinguisher ALWAYS know the location of the nearest first 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
14. 17 Generator Troubleshooting Symptom Possible Problem Solution No Voltage Output Check and replace Low Voltage Output A Check load and repair ee DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 49 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 CHECK BUTTON 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 06 MANUAL OFF RESET Figure 70 Auto Off Reset Switch Manual Position 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 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
15. 2 04 4 3 19520000504 4 4 4 4 5 4 4 6 663 5 1 M9500300004 5 2 M9500300104 5 3 M9510100403 6 1 M9503200004 6 2 4 6 3 4 7 1 9501500004 7 2 9500500104 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 85 NAMEPLATE AND DECALS ASSY PART NAME QTY REMARKS DECAL OPERATING PROCEDURES 45000060 DECAL DPF REGEN PROCEDURES 45000070 DECAL SAFETY INSTRUCTIONS 92010030 DECAL CAUTION 92010060 CONTROL PANEL AND BOX GROUP DECAL CONTROL 45000040 PLATE CHANGE OVER SW aaa aaa M92000010 PLATE VOLTMETER CHANGE OVER SW 1 92000020 DECAL WARNING ELECT SHOCK HAZ 2 M92010000 DECAL WARNING ARC Tantas M92010070 DECAL OVER CURRENT RELAY 92020040 DECAL CIRCUIT BREAKER 92200050 DECAL SET FOR OUTPUT VOLTAGE mase M92020030 DECAL SET FOR OUTPUT VOLTAGE 5 1 M92020050 ENGINE AND RADIATOR GROUP DECAL OIE DRAIN 1 90000000 DECAL WATER M90010000 DECAL WARNING ROTATING PART M90300000 DECAL WATER OIL M90300010
16. 2 1413400004 3 011008020 4 4423000512 4 4493104603 5 4423000602 4493104603 6 011008020 7 0016910025 8 M4423200004 8A M4493100004 9 0019208020 10 M4423200503 11 0019208020 12 M4433000212 13 0010114040 1 030214350 13B 031114260 13C 515455840 14 0010120050 14A 030220510 148 0041220000 146 0030020000 15 4443000202 15A 4493302804 16 0016910025 17 M4443300404 17A 4493302904 18 0019208020 19 M4443300503 19A 4493303004 20 020108060 21 M4443200403 22 M9110100204 22A 4 23 0845031504 PART NAME BASE COVER HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT COVER FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT TOP COVER FRONT FRAME HEX HEAD BOLT CENTER FRAME HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX NUT HEX HEAD BOLT WASHER LOCK WASHER FLAT HEX NUT REAR FRAME ACOUSTIC SHEET HEX HEAD BOLT COVER REAR FRAME ACOUSTIC SHEET HEX HEAD BOLT DUCT REAR FRAME ACOUSTIC SHEET HEX NUT DOOR REAR FRAME HINGE WASHER BLIND PLUG 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 5 BLACK THE SERIAL NUMBER MAY BE REQUIRED 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN QTY 1 1 2 1 1 1 10 10 1 00 R
17. 25 12 MAINTENANCE FORCED REGENERATION PROCEDURE Series 800 Controller Follow the steps below to initiate a forced regeneration Engine Started DPF STAT Sii M 1 Verify that the AMBER pre alarm LED is ON or FLASHING and the DPF symbol is shown on the O 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 pes and select FORCE REGEN mode 7 1 5 Press and hold the request until the REGEN ACTIVE Figure 60 ECU DPF Engine Shutdown message is displayed on the screen then release NOTICE 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 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 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 NOTICE Soot and ash will accumulate in the DPF over time and must be cleaned The ash is a result
18. Full Fuel Tank DO NOT OVERFILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 32 Fuel EXPANDS When Heated Figure 32 Fuel Expansion DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 29 INSPECTION SETUP COOLANT ANTIFREEZE SUMMER COOLANT WATER Cummins recommends antifreeze summer coolant for use in their engines which can be purchased in concentrate and mixed with 5096 demineralized water or pre diluted See the Cummins Engine Owner s Manual for further details If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap QV 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 and the markings Table 10 Coolant Capacity Engine and Radiator 11 4 gal 43 liters 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 Freezing Point NOTICE When the antifreeze is mixed with water the ant
19. INFORMATION 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 specifically 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 Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury 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 Safety Hazard Lethal exhaust gas hazards W Explosive fuel hazards ADSI pee Burn hazards Overspeed hazards Rotating parts hazards Pressurized fluid hazards Electric shock hazards PAGE 6 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV
20. N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by ONLY NOT USED ON 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 PAGE 52 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 SUGGESTED SPARE PARTS DCA220SSCU DCA220SSCU4I WHISPERWATT GENERATOR WITH CUMMINGS QSB7 G6 DIESEL ENGINE 1 0 3 UNITS Qty P N Description ee Y0602015150 HOSE RADIATOR HUMP Y0602015151 HOSE RADIATOR Y0602015152 HOSE RADIATOR ms 0602015153 HOSE RADIATOR Y0602015246 BELT FAN 1 4921517 SENSOR OIL PRESSURE 1 Y0602211320 SWITCH COOLANT LEVEL Y0602042578 FUEL FILTER CARTRIDGE 0602042579 CARTRIDGE WATER SEPERATOR Y0602041296 FILTER OIL CARTRIDGE ee AF55014 ELEMENT AIR CLEANER PRIMARY AF55308
21. auxiliary circuit breakers in the ON closed position 1 Place the main G F C I and aux circuit breakers Figure 35 in the OFF position prior to starting the engine MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER 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 INCORRECT Figure 36 Engine Enclosure Doors STARTING MANUAL 1 Place the engine speed switch Figure 37 the LOW down position LOW DOWN Figure 37 Engine Speed Switch Low 2 Place the Auto Off Reset Manual Switch in the MANUAL position to start the engine Figure 38 AUTO gt MANUAL OFF RESET 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 NOTICE Engine will pre heat automatically in cold weather conditions Glow Plug Hold message will
22. 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 HIGH U Figure 39 Engine Speed Switch High 4 The generator s frequency meter Figure 40 should be displaying the 60 cycle output frequency in HERTZ 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 generator s AC voltmeter Figure 41 will display the generator s output in VOLTS If the voltage is not within the specified tolerance Figure 41 Voltmeter Use the voltage adjustment control knob Figure 42 to increase or decrease the desired voltage DECREASE INCREASE 5 Figure 42 Voltage Adjust Control Knob 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 43 Ammeter No Load 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 6
23. 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 Table 9 Recommended Motor Oil F OIL SAE 122 50 104 40 9 86 30 68 20 5 8 um se 50 10 F 1 5 4 20 Oo 22 I 30 5 40 4 5 FUEL CHECK DANGER Fuel spillage on a hot engine can cause afire 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 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
24. night panel light illuminates control panel for ease of reading meters and gauges Make sure oanel light switch is inthe OFF position when light is not in use Panel Light Switch When activated will turn on control panel light Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 5 10 11 12 14 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch AC Voltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 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 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 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 Engine Speed Switch This switch controls the speed of the engine low high Auto Start Switch This switch selects either manual or automatic operation C
25. 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 ENGINE cleaning ash from the DPF is every 6 months 5000 hours 2 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 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 Braking System System employed in stopping the trailer Typical braking systems are electric surge hydraulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry including the fuel cell empty Frame Length Measurement is from the ball hitch t
26. over current relay is located in the control box Figure 11 Over Current Relay NOTICE 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 PAGE 22 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 LOAD APPLICATION 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 Single phase induction mot
27. 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 B Forced Stationary Regeneration A forced regeneration only occurs when the operator has initiated this action at the ECU and th
28. such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts 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 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 co
29. the towing vehicle Application Indicates which units can be employed on a particular trailer PAGE 42 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 TRAILER MAINTENANCE 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 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
30. 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 p
31. which can cause severe bodily harm or even death Table 7 Voltages Available UVWO Output Voltage Change Over Board Voltage Change Over Board Terminal Lugs 3 Phase 240 139V Position 3 Phase 480 270V Position 3 Line Line 208V 220V 240V 416V 440V 480V 10 Line Neutral 120V 127V 139V 240V 254V 277V Voltage Change Over Board Single Phase 240 120V Position 10 Line Neutral 120V 240 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 DCA220SSCU DCA220SSCUMi Rated Voltage 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 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 JUMPER 6 PLACES Figure 13 Voltage Change Over Board 240 36 Position A
32. 200005 19 4236100703 20 0805009804 21 012212045 22 031112230 23 0030012000 24 0605011505 25 0027105016 26 4236400204 27 0016906016 28 4260600104 28 1 0 29 011206020 30 0601808803 31 0601808804 32 0601814014 33 0601814013 34 7538070 34A OEMAA8 35 0601850275 36 0601815194 37 7538070 38 0603306775 39 7538070 40 0017110025 40A 0040510000 41 4236100604 42 4236400304 43 0016906016 44 4236400004 45 4236400104 46 011206020 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 69 PART NAME TERMINAL BOARD OUTPUT TERMINAL BOLT TIE BOLT TERMINAL PLATE HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT TERMINAL COVER HEX HEAD BOLT HINGE MACHINE SCREW HEX NUT WASHER FLAT MACHINE SCREW HEX NUT OUTPUT WINDOW SET SCREW WASHER LOCK WASHER FLAT RING TERMINAL COVER STAY RUBBER HEX HEAD BOLT WASHER FLAT HEX NUT STAY MACHINE SCREW COVER HEX HEAD BOLT BRACKET CIRCUIT BREAKER RUBBER CUSHION HEX HEAD BOLT CIRCUIT BREAKER 1P 20A CIRCUIT BREAKER 2P 50A RECEPTACLE CS 6369L 50A RECEPTACLE GF 20LA 20A MACHINE SCREW HEX NUT GROMMET TERMINAL BLOCK MACHINE SCREW BLIND PLUG MACHINE SCREW HEX HEAD BOLT TOOTHED WASHER INSULATING COVER BRACKET HEX HEAD BOLT CABLE OUTLET COVER SUPPORTER CABLE OUTLET COVER HEX HEAD BOLT QTY CSA dS d EORR ET N Aa DN OUTPUT TERMINAL ASSY REMARKS
33. 5 psi 193 586 kPa 4 OIL PRESS Figure 44 Oil Pressure Gauge 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 10 11 12 Figure 45 Coolant Temperature Gauge 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 Figure 46 Engine Tachometer Gauge Place the main GFCI and aux circuit breakers in the ON position Figure 47 MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER lalallala Figure 47 Main Aux and Circuit Breakers ON Observe the generators 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 33 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
34. ACKET HEX HEAD BOLT U BOLT SET EXHAUST TAIL PIPE HARNESS CLAMP HEX HEAD BOLT GROMMET EXHAUST INSULATING WRAP HOSE BAND CLAMP HEX HEAD BOLT QTY 1 1 4 2 2 2 1 1 1 1 1 1 1 4 1 1 1 2 1 1 4 1 1 MUFFLER ASSY REMARKS DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 73 FUEL TANK ASSY PAGE 74 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 4363000202 1 1 0605505070 2 4363200004 3 9310500104 4 011008020 5 0207308000 6 0191302300 7 Y0191204000 8 0605515109 9 Y0602042579 10 014210040 11 Y0602022578 12 Y0602022985 13 0602220911 13A 0016906016 14 M1363400104 15 0605515198 16 1502025103C 17 011206020 18 0802011104 18A 0150000018 PART NAME FUEL TANK FUEL TANK CAP TANK BAND SUPPORTER SHEET HEX HEAD BOLT SUPER LOCK NUT SUCTION HOSE RETURN HOSE HOSE BAND CART FUEL WATER SEPARATOR HEX HEAD BOLT 90 ELBOW HOSE JOINT CLAMP HEX HEAD BOLT DRAIN HOSE HOSE BAND DRAIN JOINT HEX HEAD BOLT DRAIN BOLT O RING QTY 1 1 2 4 2 2 1 1 4 1 2 1 1 1 1 1 2 1 2 1 1 FUEL TANK ASSY REMARKS DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 75 ENCLOSURE ASSY PAGE 76 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 ENCLOSURE ASSY NO PART 1 4413000412
35. 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 inflated 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 i 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 knifing 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
36. ANGE 2 WHITE 3 SPECTRUM GREY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN QTY REMARKS 00 GC a CE OS DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 79 ENCLOSURE ASSY CONT PAGE 80 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 50 M4453001603 50 4 51 M4453001703 51 4 52 4453301104 52 04 53 4453301204 53 1 4493407904 54 4453301304 54 4493408004 55 M4453301404 55A 4 56 020108060 57 9114000002 58 9113000102 59 0021806018 59A 020106050 60 4453600004 61 4453600104 62 0019206015 63 0845046904 63A 4 64 0845047004 64 9116100004 65 0019208020 66 0601850097 67 0027208025 68 0845031504 SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT DOOR HANDLE DOOR HANDLE MACHINE SCREW HEX NUT GUTTER GUTTER HEX HEAD BOLT HINGE WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW BLIND PLUG 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 5 BLACK THE SE
37. C 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 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 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 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
38. Check bearing adjustment and balance tires Flat Spots Wheel lockup and Avoid sudden stops when 0 tire skidding possible and adjust brakes 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 SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE NUTS AXLE HANGER SUPPORT BRACKET IS WELDED NSHACKLE BOLTS LEAF FRONT HANGER NUT FRONT U BOLT HANGER BOLT LOCKING TIE PLATE NUT Figure 63 Major Suspension Components Table 15 Suspension Torque Requirements Torque Fitts Shackle Bolt Snug fit only Parts must rotate freely Locking nuts or cotter pins are Spring Eye Bolt 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 TRAILER MAINTENANCE Lug Nut Torque Requirements Itis 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 Figu
39. D H Hs BS BS SONS SN 1 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 61 CONTROL BOX ASSY CONTINUED PAGE 62 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART NO 28 0027105016 29 4273000003 30 011208030 31 8181852104 32 0917106025 33 8181853104 34 4276200004 35 012210020 36 0041410000 37 0040010000 38 014210040 38A 021112140 39 0601808646 40 4213600104 41 952404470 42 505015300 43 0330000250 44 0027104020 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 63 CONTROL BOX ASSY CONTINUED QTY PART NAME MACHINE SCREW TERM BD VOLTAGE CHANGE OVER HEX HEAD BOLT CHANGE TERMINAL HEX HEAD BOLT CHANGE OVER PLATE CHANGE PLATE TIE BOLT WASHER FLAT WASHER LOCK HEX HEAD BOLT SELF LOCKING NUT FUSE 20A STOPPER CONTROL PANEL WASHER FLAT SNAP PIN EDGING MACHINE SCREW 4 1 4 10 20 6 3 26 26 26 3 ENGINE AND RADIATOR ASSY te alli yr Es PAGE 64 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 ENGINE AND RADIATOR ASSY NO PART PART NAME QTY REMARKS 1 M4923200054 ENGINE CUMMINS QSB7 G6 1 1A 0602015246 FAN BELT 1 1 1 Y0602046648 ELEMENT AIR CLEANER INNER 1 1 49 ELEMENT A
40. E REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD CONNECT TO EXTERNAL 120 VAC POWER SOURCE Figure 58 Battery Charger and Jacket Water Heater Power Connections 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 39 MAINTENANCE EMISSION CONTROL The emission control system employed with the Cummins QSB amp 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
41. E PHASE 480 VAC LOAD CONNECTIONS Figure 25 UVWO Terminal Lugs 10 480 Connections 10 277 UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 23 Connect the load wires to the UVWO terminals as shown in Figure 26 GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 277 VAC LOAD CONNECTIONS Figure 26 UVWO Terminal Lugs 10 277 Connections DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 27 INSPECTION SETUP 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 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
42. EMARKS DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 77 ENCLOSURE ASSY CONT PAGE 78 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 ENCLOSURE ASSY CONT NO PART 24 0019208020 25 0601850097 26 0027208025 27 4443600004 28 020106050 28A 952404470 29 0600800320 30 0021806016 31 9114000002 32 0021806016 32A 020106050 33 4463100302 4493503004 34 0019208020 35 M3310600004 36 0019208020 37 4463200502 3 A 4493503103 38 0019208020 39 0017110025 40 4463200304 41 0016908016 42 4463200603 42A M4493503204 43 0016908020 44 4463500204 45 0019206015 46 4453200202 46 14493403604 47 0019108065 47A 0042308000 47B 0 48 4453001403 48 4 49 4453001503 49 14493407504 PART HEX HEAD BOLT STOPPER MACHINE SCREW WINDOW PLATE SELF LOCKING J NUT WASHER FLAT MANUAL PACK MACHINE SCREW DOOR HANDLE MACHINE SCREW HEX NUT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT COVER HEX HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT COVER HEX HEAD BOLT DUCT REAR ROOF ACOUSTIC SHEET HEX HEAD BOLT GUTTER HEX HEAD BOLT SPLASHER PANEL ACOUSTIC SHEET HEX HEAD BOLT WASHER LOCK WASHER FLAT SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 OR
43. HEX SOCKET HEAD CAP SCREW WASHER LOCK WASHER FLAT FAN COUPLING DISK WASHER COUPLING HUB BALANCING TY ed INCLUDES ITEMS W GENERATOR ASSY REMARKS imu WHEN PURCHASING BALANCING PLATE ITEM 1 11 MUST ALSO BE M M 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 p ADD n GENERATOR ASSY CONTINUED PAGE 56 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 15 61154400103 16 011106015 17 012112040 18 0042512000 18 1 031112230 19 61132300114 20 0010006030 20 952404470 208 020106050 21 0605000012 22 0030020000 22A 030220510 23 M3163600103 24 012010030 25 030210250 26 M3163700004 27 0070506207 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 57 GENERATOR ASSY CONTINUED PART NAME SUCTION COVER HEX HEAD BOLT HEX
44. HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 4213000212 2 011008020 3 M4213400104 4 4213500104 5 011008020 6 4260500103 7 011008020 8 0602201456 9 0602201457 10 0016906016 1 0601821370 12 0027104020 13 LY2DUS24VDC 13 138 14 0027104020 15 0601872130 15A 0601806603 16 0601815153 17 0027104020 18 0601802218 18A 0601806671 18B 0601802131 18C 0601802133 19 0027103020 20 0601809667 21 0027106020 22 Y0801820847 23 0601820848 24 0027104020 24 OEMAA8 25 Y0601807523 25 1 0601827412 26 014210040 26A 021112140 27 0601820604 PART CONTROL BOX HEX HEAD BOLT BACK PANEL TOP PANEL HEX HEAD BOLT SET PANEL HEX HEAD BOLT MAGNETIC SWITCH MAGNETIC SWITCH HEX HEAD BOLT RECTIFIER MACHINE SCREW RELAY S dt susu RELAY BASE a n E RELAYGLIPS Sana au aa MACHINE SCREW HOLDER FUSE FUSE 150A TERMINAL BLOCK MACHINE SCREW HOLDER FUSE FUSE LEFT 15 FUSE CENTER 1A FUSE RIGHT MACHINE SCREW CURRENT TRANSFORMER MACHINE SCREW OVER CURRENT RELAY OVER CURRENT RELAY MACHINE SCREW HEX NUT CIRCUIT BREAKER 3P 600A REAR TERMINAL BUSBAR HEX HEAD BOLT SELF LOCKING NUT AUTOMATIC VOLTAGE REGULATOR CONTROL BOX ASSY QTY REMARKS 1 14 1 1 m REPLACES P N 0601827655 REPLACES P N 0601823109 REPLACES P N 0601824400 OD PO PP WN
45. I I I I 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 Voltage Change Over Board 240V Set AVR CONNECTOR VIEW FROM INSERTING WIRE SIDE 12 CIRCUIT BREAKER SIDE 081 CONNECTOR VIEW FROM INSERTING WIRE SIDE Voltage Change Over Board 480V Set CONNECTOR EW FROM INSERTING WIRE SIDE COLOR CODE wmEcoLoR __ COLOR B BLACK RIRED BR BROWN Y YELLOW ORANGE P PiNK CONTROL BOX CONTROL PANEL Figure 67 Generator Wiring Diagram SYMBOL DESIGNATION SYMBOL DESIGNATION EXCITERARMATURE WINDING AC VOLTMETER 0 600V ExFg 07 010086 F FREQUENCY METER 45 65 Hz AVR AUTOMATIC VOLTAGE REGULATOR PL1 PILOT LAMP VR VOLTAGE REGULATING RHEOSTAT CB2 3 CIRCUIT BREAKER 20A Re RECTFER 4 6 AUX CIRCUIT BREAKER 50A CT1 3 CURRENT TRANSFORMER 750 5A CON2 3 RECEPTACLE 5208 GFCI 20A 125V 0 CIRCUIT BREAKER 800 AMPS ON3 5 RECEPTACLE CS 6369 50A 120 240V OVER CURRENT RELAY iL PANEL LIGHT IL CHANGE OVER BOARD PANEL LIGHT SWITCH IAMMETER CHANGE OVER SWITCH DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 47 ENGINE WIRING DIAGRAM SS
46. IR CLEANER OUTER 1 1 2 RBX002252 AIR CLEANER INDICATER 1 1 3 6 CARTRIDGE OIL FILTER 1 1 4 0602042578 CARTRIDGE FUEL FILTER 1 2 4303200603 ENGINE FOOT 1 3 4303200703 ENGINE FOOT 1 4 0131151240 HEX HEAD BOLT 6 4A 0040012000 WASHER LOCK 6 5 M4357300103 HARNESS CLAMP 1 6 0191701800 BLOWBY HOSE 1 7 0605515149 HOSE BAND 2 8 Y0602022588 ADAPTER 1 9 Y0602022579 90 ELBOW 1 10 Y0379500800 DRAIN HOSE 1 11 Y0603306399 HOSE JOINT 1 12 Y0605511399 VALVE 1 13 Y0603306597 CONNECTOR 1 14 Y0603300286 LOCKNUT 1 15 Y0602021071 CAP 1 16 Y0602012739 RADIATOR CAC ASS Y 1 17 Y0602011024 CAP RADIATOR 1 18 Y0343207038 HEX HEAD BOLT 2 18A 0043007000 WASHER LOCK 2 18B 0043107000 WASHER FLAT 2 19 4310201514 BRACKET 2 20 0343206120 HEX HEAD BOLT 2 20A 030206150 WASHER LOCK 2 20B 0043106000 WASHER FLAT 2 21 0016310025 HEX HEAD BOLT 4 22 Y0602013263 TUBE CAC HOT SIDE 1 23 0602014823 TUBE COLD SIDE 1 24 0602015150 HOSE HUMP 3 24A 0605515258 CLAMP HOSE 6 25 Y0602014822 TUBE WATER INLET 1 26 0602015151 HOSE 70 175 L 5 00 2 26A 0605515257 CLAMP HOSE 4 27 Y0602326067 U BOLT SET 1 28 0602013262 TUBE WATER OUTLET 1 29 0602015152 HOSE 70 175 L 5 00 2 29A 0605515256 CLAMP HOSE 4 30 0602015153 HOSE 70 100 1 52 1 30A 0605515259 CLAMP HOSE 2 31 0605512198 HOSE JOINT 4 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 65 ENGINE AND RADIATOR ASSY CONTINUED PAGE 66
47. NCE If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to aloss 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 Figure 56 Fuel Tank Cleaning 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 Fu
48. OPERATION AND PARTS MANUAL MULTIQUIP POWER 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 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 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 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenue S E Wash
49. RIAL NUMBER MAY BE REQUIRED DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 81 6 CATERPILLAR YELLOW 7 CATO GOLD 8 RED 9 DESERT TAN ENCLOSURE ASSY CONT QTY REMARKS RUBBER SEALS ASSY PAGE 82 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 0 4 0229201300 0229201200 0228901120 0228901260 0228900660 0228900795 0228901055 0228901200 0228900600 0229400630 0228801050 0228800590 0228100560 0228100370 0222100120 0222100180 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 83 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 MUMIA ORR REMARKS NAMEPLATE AND DECALS ASSY PAGE 84 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NO PART 1 1 M4550000603 1 2 4550000703 1 3 9520100304 1 4 9520100603 2 1 4550000402 2 2 9520000104 2 3 M9520000204 2 4 19520100004 2 5 9520100704 2 6 9520200404 2 7 9522000504 2 8 9520200303 2 9 9520200504 3 1 9500000004 3 2 M9500100004 3 3 M9503000004 3 4 9503000103 3 5 9503100004 3 6 9510100004 4 1 4550000503 4
50. T 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 Allow engine to cool when flushing out JM 7 radiator Flushing the radiator while hot A could cause serious burns from water or steam 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
51. TOR OPERATION MANUAL REV 0 10 25 12 PAGE 43 TRAILER MAINTENANCE 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 ALWAYS wear safety glasses when gt removing or installing force fitted parts Failure to comply may result in serious injury DO NOT attempt to repair or modify a ET 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 Table 14 Tire Wear Troubleshooting Center Wear Over inflation Adjust to particular load per tire manufacturer Edge Wear Under inflation Adjust to particular load per tire manufacturer Make sure load does not Loss of camber Side Wear exceed axle rating or overloading Align wheels Cupping Outof balahce
52. 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 DECREASE INCREASE Figure 9 Voltage Regulator Control Knob 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 CS 6369 TWIST LOCK RECEPTACLES HARD WIRE HOOKUP PANEL LOAD 4 RECEPTACLE LOAD NEUTRAL Figure 10 Connecting Loads 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
53. al components Paint chemicals and lubricants Decals and paper products Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 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 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 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 11 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 e 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
54. ambulance doctor and fire department This information will be invaluable in the case of an emergency GENERATOR SAFETY DANGER NEVER operate the equipment an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death 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 NEVER lubricate components or attempt service on 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 SAFETY INFORMATION ENGINE SAFETY 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 flow of cooling air NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted If t
55. ames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur ALWAYS wear safety glasses when handling the battery to avoid eye irritation The battery 2 contains acids that can cause injury to the eyes and skin B 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 W f the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water W f 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 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 ENVIRONMENTAL SAFETY NOTICE B Dispose of hazardous waste properly Examples of potentially hazardous waste used motor oil fuel and fuel filters DO NOT use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil or fuel direct
56. came Wamaq Cam ier MO CRT efas f 1 57 t 13 0 34 4 95 pc 7H LIGET lt FUSES 1504 4 rz x mmm AUTO MANUAL 8 STOP BUTTON 77 11985 68 CHANGR OYZR 57 FUSE3 154 J 3 C r 1 ENGINE yi s4 2 START 2 I 0 9 11 I 11 or 1 281 1 ACC tae 4021 PA i pz vc pum mu d BY USER FUSE HOLDSR ASST eh E i gt gt 1 T B 4 m 7 23 NM SEIELD 58 CH8 011 CN7 UAM 7 denser 1055 IDLE RUN e D gPa 6 3 ATA 1 ENGINE 30 Y 2380 1 SRITCE CUMMINS ENGINE CONTROL UNIT CM2250 FUEL LEVEL UNIT COLOR CODE ___ WIRECOLOR __ WIRE COLOR RED 8 BLACK BuE W wurEe BR BROWN Y YELLow G GREEN _ LB LIGHTBLUE O ORANGE Plew Figure 68 Engine Wiring Diagram CN6 CN7 pl ES 1 5 E6 E7 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 Table
57. caused the most recent shutdown 6 After perfoming diagnostic tests place the Auto Off Reset Manual Switch in the OFF position PAGE 50 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 NOTES DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 51 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 PARTNO 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 AR MAKE LOCALLY 4 12349 BEARING 1 6 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol Q or gt 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 be
58. coolant 5 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm 25 in H20 f blowby hose needs to be replaced ensure that the slope of the blowby hose is at least 1 2 inch per foot with no sags or dips that could collect moisture and or oil GENERAL INSPECTION AIR CLEANER INDICATOR 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 AIR CLEANER ELEMENT Figure 55 Air Cleaner Indicator compressed air Replace the air cleaner as needed NOTICE Air Cleaner with Dust Indicator The air filter should not be changed until the indicator This indicator is attached to the air cleaner When the air reads RED Dispose of old air filter It may not be cleaner element is clogged air intake restriction becomes cleaned or reused 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 PAGE 36 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 MAINTENA
59. e ECM recognizes a pre programmed 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 ECU Series 800 Controller Engine Started STAT 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 pre determined level and a Forced Regeneration action is required NOTICE 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 PAGE 40 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10
60. el 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 37 MAINTENANCE To restart after running out of fuel turn the switch to the 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 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 OU
61. en 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 clarified 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 clarified 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
62. enter position is OFF reset Hour Check Button With the engine stopped press and hold ths button The total running hours fuel level and battery voltage will be displayed Main Circuit Breaker This three pole 600 amp main breaker is provided to protect the U V and W Output Terminal Lugs from overload DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 19 OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel Figure 7 shown below is The Output Terminal Panel Figure 7 is provided with located on the right hand side left from control panel of the following the generator Lift up on the cover to gain access to receptacles and terminal lugs Three 3 240 139V output receptacles 50 NOTICE E Three 3 Circuit Breakers 50 amps Terminal legs and Ground are considered bonded grounds 2 GFCI Circuit Breakers 20 amps Eight 8 Output Terminal Lugs U V W Ground MQ POWER 10 AND 39 NEUTI GROUND TERMINAL TERMINAL 120 OUTPUT TERMINALS CIRCUIT BREAKERS 1 ES CIRCUIT BREAKERS FOR GFCI RECEPTACLES FOR CS 6369 TWIST ub LOCK RECEPTACLES 120 VAC 20 AMP Y RECEPTACLES x 0 CS 6369 TWIST LOCK AUX POWER RECEPTACLES 240 139V 50 AMPS Figure 6 Output T
63. erminal Panel PAGE 20 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC Receptacles There 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 120 VAC GF C l RECEPTACLE BUTTON TEST BUTTON Figure 7 G F C l 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 5 6369 TWIST LOCK RECEPTACLES SINGLE PHASE 240 139 VAC 50 AMP OUTPUT Figure 8 240 139V Twist Lock Auxiliary Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker
64. from the factory in the 240V configuration The voltage regulator VR allows the user to increase or decrease the selected voltage 30 240V UVWO Terminal Output Voltages 1 Jumper the voltage change over board for 240V operation as shown in Figure 18 JUMPER 6 PLACES a ej 2 le 3 Figure 18 Voltage Change Over Board 240V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 19 GROUND CONNECTION MUST BE USED ATALL TIMES THREE PHASE 240 VAC LOAD CONNECTIONS Figure 19 UVWO Terminal Lugs 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 DECREASE INCREASE Figure 20 Voltage Regulator Knob 10 240V UVWO Terminal Output Voltages 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 GROUND CONNECTION MUST BE USED AT ALL TIMES 240 MAG Leeper MEE ONS Figure 21 UVWO Terminal Lugs 10 240 Connections 10 120V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 240V operation as shown in Figure 18 2 Adjustvoltage regulator knob Figure 20 for an output of 208V to obtain 120V at the UVWO termina
65. gency stop button Figure 54 inward This button is located on the engine operating panel see ES 2 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 35 MAINTENANCE E 10 Hrs 1000 Table 12 Inspection Maintenance DAILY 250 Hrs 500 Hrs Hrs Check Engine Fiuidlevels X ET Check AirCleaner Check Battery AcidLevel L X 120 1 Check Fan 8610000166 EX CheckforLooseningofParts Jx I Replace Engine Oil and Fiter X Clean Check Fuel FiterWater Separator Bow X J Clean Unit Inside and Outside Change Fuel Fiter XT Clean Radiator and Check Coolant Protection Leve f X ____ Replace AirFilterElement oo X Check all Hoses andClamps Clean inside ofFuelTank o X Measure Insulation Resistance Ovr3Mohms X Measure Insulation Resistance Over 3M ohms Generator Check Rotor Rear Support Bearing PX Replace engine oil and filter at 100 hours first time only Add Supplemental Coolant Additives SCA S to recharge the engine
66. he air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine M DO NOT place hands or fingers inside engine compartment when engine is running NEVER operate the engine with heat shields or guards removed i Keep fingers hands hair and clothing away from all moving parts to prevent injury DO NOT remove the radiator whilethe engine is hot High pressure boiling water AR I will gush out of the radiator and severely lt lt 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 NEVER touch the hot exhaust manifold 2 muffler or cylinder Allow these parts to cool before servicing equipment NOTICE NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air filter 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 stac
67. ifreeze mixing ratio must be less than 50 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 10 15 MM DEFLECTION Figure 33 Fan Belt Tension NEVER place hands near the belts or fan AS while the generator set is running PAGE 30 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 INSPECTION SETUP 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 s
68. ing 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 ns cord or cable with wet hands The _ lt possibility exists of electrical shock RI electrocution or death Power POWER ON 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 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 PAGE 10 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 SAFETY INFORMATION 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
69. ington 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 3 DCA220SSCU SSCU4I Proposition 65 Warning 2 Reporting Safety 3 Table Of 001608 4 Safety Information 6 11 Specifications ssseseesesssesseesresressrereenrerresrrssreese 12 Dimensions iets 13 Installation sche 14 15 General Information sess 16 17 Engine Control Unit ECU 18 Engine Generator Control Panel 19 Output Terminal Panel Familiarization 20 22 Load Application a 23 Generator 24 Generator Outputs Gauge Reading 25 Output Terminal Panel Connections 26 27 Inspection Setup a eder 28 31 Generator Start Up Procedure Manual 32 33 Generator Start Up Procedure Auto Mode 34 Generator Shut Down Procedures 35 Maintenance P 36 41 Trailer Maintenance 42 45 TTrailer Wiring
70. is purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator PAGE 8 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 SAFETY INFORMATION FUEL SAFETY DO NOT start the engine near spilled fuel or combustible fluids Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited ALWAYS refuel in a well ventilated area away sparks and open flames ALWAYS use extreme caution when working with flammable liquids I DO NOT fill the fuel tank while the engine is running or hot DO NOT overfill 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 flames NEVER use fuel as a cleaning agent B 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 Check with your local county or state safety towing regulations in addition to meeting O Department of Transportation DOT Safety Towing Regulations before towing your generator Refer to MQ Power trailer manual for additional safety information order to reduce the possibility of an accident while transporting the generator on public roads
71. isions 1 Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain 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 8 Theparts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated c The list must state the reason s for the return d 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 3 Acopyofthe Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 following items are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b 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 Electric
72. king is common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operates without sufficient 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 efficiency 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 flames from the engine exhaust Spark arresters are qualified and rated by the United States Forest Service for th
73. ls 3 Connect the load wires to the UVWO terminals as shown in Figure 22 BLACX RED BLUE WHITE GREEN U V W O eS C uw ZA CS N 6 OO MO 2 9 lt 120V gt SINGLE PHASE 120 VAC LOAD CONNECTIONS Figure 22 UVWO Terminal Lugs 10 120 Connections PAGE 26 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 OUTPUT TERMINAL PANEL CONNECTIONS 30 480V UVWO Terminal Output Voltages 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 USE 2 JUMPER PLATES AT EACH POSITION Figure 23 Voltage Change Over Board 480V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 24 GROUND CONNECTION MUST BE USED ATALL TIMES THREE PHASE 480 VAC LOAD CONNECTIONS Figure 24 UVWO Terminal Lugs 30 480V 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 10 480V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 23 Connect the load wires to the UVWO terminals as shown in Figure 25 GROUND CONNECTION MUST BE USED AT ALL TIMES E
74. ly onto the ground down a drain or into any water source DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 11 SPECIFICATIONS Table 1 Generator Specifications DCA220SSCU DCA220SSCU4i Revolving field self ventilated open protected type synchronous generator Armature Connection Star with Neutral Standby Output 194 kW 242 kVA Prime Output 176 kW 220 kVA 30 Voltage L L L N Voltage Change Over Bd at 30 9 BUSTED PED t 30 Voltage L L L N Voltage Change Over Bd at 30 480 277 416 240 440 254 480Y 277 10 Voltage L L L N Voltage Change Over Bd at 10 240 120 240 120 Power Factor Frequency Speed 1800 rpm Aux AC Power Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 Dry Weight 6 636 Ibs 3 010 kg 7 496 lbs 3 400 kg Table 2 Engine Specifications Model Cummins QSB7 G6 EPA Interim Tier 4 Certified Tvpe 4 cycle water cooled direct injection turbo charged yp air cooled and EGR No of Cylinders 6 cylinders Bore x Stroke 4 21 in x 4 88 in 107 mm x 124 mm Displacement 409 cu in 6 7 liter Rated Output 282 HP at 1800 rom Starting Fuel Consumption 9 5 gal 36 0 L hr at 3 4 load 4 4 gal 16 8 L hr at 1 4 load 27 CCA 0 F 800A X 2 Includes engine and radiator hoses 2 Includes filters in 67 liter Coolant Capacity 11 4 gal 43 0 liters Lube Oil Capacity 4 6 gal 17 5 liters PAGE 12
75. meter 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 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 Two 120V output receptacles GFCI 20A Two circuit breakers 204 Eight output terminal lugs 30 power Ground lug Battery Charger Optional B Jacket Water Heater Optional 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
76. nd 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 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 The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel NEVER manually start the engine with the main or
77. nnected 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 b Aluminum 6 AWG 8 4 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 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 15 GENERAL INFORMATION 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 Controller Gauge Unit Assembly Oil Pressure Gauge Water Temperature Gauge Charging Voltmeter Fuel Gauge Tacho
78. not use H Program Exit Button Pushing this button allows the DPF Force Regen and diagnostic code to be confirmed PAGE 18 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 ENGINE GENERATOR CONTROL PANEL 18 42 24 6 BATTERY Figure 5 Gauge Unit Assembly 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 Panel Light For operation at
79. o the rear bumper reflector Frame Width Measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type of hitch used on the trailer for towing 10 1 12 13 14 15 16 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 Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc Wheel Hub The wheel hub is connected to the trailer s axle Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire 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 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 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride Electrical Electrical connectors looms are provided with the trailer so the brake lights and turn signals can be connected to
80. onnecting 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 5615 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 23 GENERATOR OUTPUTS 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 JUMPER 6 PLACES Figure 12 Voltage Change Over Board 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
81. ons 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 2 MULTIQUIP
82. ors 0 4 0 75 Electric heaters incandescent lamps Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Common power tools Table 6 Cable Selection 60 Hz Single Phase Operation s 25 s mos sew 201 5 o to soon soon aon vs rs sw wer o _ e 108 so ison 0 6 ww 5 CAUTION Equipment damage can result from low voltage THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 KVA NOTICE If 30 load kVA is not given on the equipment nameplate approximate 30 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 5 rated output kW can be used When connecting a fluorescent or mercury lamp capacity of up to the generating 5 rated output KW multiplied by 0 6 can be used When c
83. ower 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 PAGE 16 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 MAJOR COMPONENTS MQ POWER Table 4 Generator Major Components ITEM NO DESCRIPTION Muffler Assembly 6 FuelTankAssemby 8 Circuit Breaker Assembly 9 ___ Auto Start Stop Controller Assembly Figure 3 Major Components DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 17 ENGINE CONTROL UNIT ECU ECU Series 800 Controller Engine Started 9 Shutdown Pre Alarm DL 8 9 P ES 3 e eq 00 e Figure 4 Engine Control Unit ECU The definitions below describe the controls and functions of the Engine Control Unit Figure 4 1 ECU Controlle
84. 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 DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 89 OPERATION MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Mul
85. r 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 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 blinking until all fault messages 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
86. re 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 Table 16 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 45 40 50 65 5100 NUTS 8406 NUTS 20 25 35 40 50 65 E aly n 20 25 50 60 90 120 97 20 25 50 60 90 120 PNEUMATIC AIR GUN TORQUE WRENCH Figure 64 Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA220SSCU 4i 60 HZ GENERATOR OPERATION MANUAL REV 0 10 25 12 PAGE 45 TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE CONNECTOR CONNECTOR LEFT TAIL LIGHT 1 t i 1 1 1 1 1 DOUBLE FILAMENT BULB CONNECT TO CHASSIS TAIL LIGHT oe 1 i SINGLE i FILAMENT 1 BULB GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT 1 DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT i 1 1 1 DOUBLE i FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT oe WHITE SINGLE FILAMENT BULB RED TURN LEFT LICENSE TAIL LIGHT I I DOUBLE FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND 1 t I
87. system may occur without this transfer switch 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 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 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 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 Place the Engine Speed Switch Figure 49 in the HIGH position 4 HIGH UP Figure 49 Engine Speed Switch High Place the Auto Off Reset Manual Switch Figure 50
88. tarting 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 ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE C 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 a
89. the generating set and store a clean dry place Disconnect the battery Make sure engine coolant is at proper level E f 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 PAGE 38 DCA220SSCU 4i 60 HZ GENERATOR OPERATION AND PARTS MANUAL REV 0 10 25 12 MAINTENANCE 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 OUTPUT TERMINAL PANEL BATTERY CHARGER 120 VAC INPUT RECEPTACLE JACKET WATER HEATER 120 VAC INPUT RECEPTACL
90. tiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact mq multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Tel 800 421 1244 Fax 310 537 3927 Fax 310 537 4259 Fax 310 943 2238 MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 943 2249 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta cipsa com mx Tel 52 222 225 9900 Fax 52 222 285 0420 Tel 0161 339 2223 Fax 0161 339 3226 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com 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 specificati

Multiquip DCA220SSCU4i User's Manual

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