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Multiquip DCA-220SSVU Portable Generator User Manual

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Contents

1. 70 71 Muffler Assembly 72 73 Fuel Tank Assembly 74 75 Enclosure Assembly 76 79 Rubber Seals 0 80 81 Nameplate and Decals 82 83 Terms and Condition of Sale Parts 84 Specification and part number are subject to change without notice PAGE 4 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ PARTS ORDERING PROCEDURES When ordering parts please supply the following information Dealer account number Dealer name and address Shipping address if different than billing address Return fax number Applicable model number Quantity part number and description of each part Specify preferred method of shipment Note Unless otherwise indicated by customer all FedEx or UPS Second Day or Third Day orders are treated as Standard Orders and will FedEx or UPS Next Day ship within 24 hours We will make every effort to Federal Express Priority One ship Air Shioments the same day that the order is DHL received if prior to 2PM west coast time Stock Tud Orders must be so noted on fax or web forms ouuu
2. Output Terminal Panel Familiarization OAC ae Generator AN gaude Output Terminal Panel Connections Generator Start up Procedure Manual Generator Start up Procedure Auto Mode 38 Generator Shut Down Procedure 39 Maintenance 40 41 Jacket Water Heater battery Charger Option 42 Maintenance Trailer 2 43 46 Trailer Wiring Diagram 47 Generator Wiring Diagram 48 Engine Wiring Diagram 49 Generator Troubleshooting 50 Engine Controller Troubleshooting 51 Explanation of Code in Remarks Column 52 Suggested Spare Parts 53 COMPONENT DRAWINGS Generator 2 54 57 Control Panel Assembly 58 59 Control Box Assemb y 60 63 Engine and Radiator Assembly 64 67 Output Terminal Assembly 60 69 Battery 5
3. 55555 Here s how to get help Place Your Parts Order Via Web or Fax i Please have the model and serial number For Even More Sa on hand when calling Domestic USA Dealers Only MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Extra Discounts Carson CA 90746 FAX 310 632 2656 All parts orders which include complete part numbers and Email mqpower multiquip com are received by our automated web parts order system or Internet www mqpower com by fax gualify for the following extra discounts PARTS DEPARTMENT Ordered Standard Stock orders 800 427 1244 FAX 800 672 7877 via orders 750 list and above 310 537 3700 FAX 310 637 3284 Fax 3 10 SERVICE DEPARTMENT Web 5 10 6 FAX 310 638 8046 Special freight allowances TECHNICAL ASSISTANCE When you order 10 or more 800 835 2551 FAX 310 638 8046 line items via Web or Fax WARRANTY DEPARTMENT FedEx Ground Service at no charge for freight 800 835 2551 EXT 279 FAX 310 638 8046 No other allowances on freight shipped by any other carrier 310 537 3700 EXT 279 Common nuts bolts and washers all items under 1 00 list price do not count towards the 10 line items NOTE DISCOUNTS ARE SUBJECT TO CHANGE Direct TOLL FREE access m POST OFFICE BOX 6254 to our Parts Department 4 4 e CARSON CA 90749 p 310 537 3700 800 421 1244 Toll free nationwide 800 427 1244 POWER FAX 310 632 2656 E MAIL mgpower
4. Listen for any abnormal noises If any abnormalities exists shutdown the engine and correct the problem If the engine is running smoothly place the engine speed switch Figure 43 in the HIGH up position HIGH UP tO Figure 43 Engine Speed Switch High AUTO MANUAL OFF RESET 5 Verify that the Engine Running status LED on the MPEC unit Figure 44 is ON it after the engine has been started LOW OIL PRESSURE HIGH COOLANT TEMPERATURE O OVERCRANK O OVERSPEED ENGINE RUNNING Figure 44 Engine Running LED ON PAGE 36 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 8 The ammeter Figure 48 will The engine oil pressure gauge DCA 220SSVU 50 HZ GENERATOR START UP PROCEDURE MANUAL 6 The frequency meter Figure 45 should be displaying the 60 cycle output frequency in HERTZ Figure 45 Frequency Meter Hz 7 The generator s AC voltmeter Figure 47 will display the generator s output in VOLTS If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 47 to increase or decrease the desired voltage Figure 46 Voltmeter 10 The coolant temperature gauge 11 Figure 50 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 165 and 203 degrees Fahrenheit Green Zone Figure 50 Coolant Temp
5. BC lt cc O A O lt LLI O lt LLI N e LO 5 2 P gt 7 S xapmew anwe 0 1 2 2 gt bos N Nau 18 D 1934384 iL 20066153 LINN 03345 DCA xa 13431 ene 1593 an meg 84 1 gt ud i hg 2 IM L g XXng HOLIMS GATT 181002 1 e lt Lu lt lt S gt Lu cc lt lt lt o cc lt a lt lt lt lt ja m LLI O M 2 gt 9 O CN 5 lt O O DCA 220SSVU 50 HZ TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 18 shown below for diagnosis of the Generator If the problem cannot be remedied consult our company s business office or service plant TABLE 18 GENERATOR TROUBLESHOOTING PAGE 50 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ TROUBLESHOOTING ENGINE CONTROLLER Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 Engine Controller Troubleshooting as a basic guideline for troubleshooting the Microprocessor Engine Contr
6. CA 90746 FAX 310 632 2656 Email mqpower O multiquip com Internet www mqpower com PARTS DEPARTMENT 800 427 1244 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 835 2551 FAX 310 638 8046 310 537 3700 TECHNICAL ASSISTANCE 800 835 2551 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 EXT 279 FAX 310 638 8046 310 537 3700 EXT 279 Manufactured for Multiquip Inc by DENYO CO LTD JAPAN Your Local Dealer is MQPOWER A Division of Multiquip Inc AN POST OFFICE BOX 6254 CARSON CA 90749 310 537 3700 800 421 1244 FAX 310 632 2656 POWE E mail mgpower multiquip com Internet www mqpower com
7. DCA 220SSVU 50 HZ GENERAL INFORMATION DCA 220SSVU 50 Hz Whisperwatt Series Familiarization Generator The MQ Power Model DCA 220SSVU 50 Hz is a 176 kW generator Figure 5 that 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 Engine Operating Panel The Engine Operating Panel is provided with the following Tachometer Water Temperature Gauge Oil Pressure Gauge Charging Ammeter Gauge Fuel Level Gauge Pre Heat Button Engine Speed Switch Panel Light Panel Light Switch Auto ON OFF Engine Controller MPEC Coolant Level Alarm Lamp Generator Control Panel The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Voltage Regulator 3 Pole 600 amp Main Circuit Breaker Control Box located behind the Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay Voltage Rectifer Starter Relay Engine Controller Computer Controlled Voltage Selector Switch Output Terminal Panel The Output Terminal Panel is provided with the following Three 100 200V output receptacles CS 6369 50A Three auxilliary circuit breakers 50A Two 100V output receptacles GFCI 20A Two GFCI circu
8. PAGE 33 DCA 220SSVU 50 HZ PRE SETUP Coolant ISUZU Antifreeze Summer Coolant Water VOLVO recommends VOLVO antifreeze summer coolant for use in their engines which can be purchased in concentrate and mixed with 50 demineralized water or pre diluted see the VOLVO Engine Owner s Manual for further details AX WARNING BURN HAZARDS If adding coolant antifreeze mix to the A radiator DO NOT remove the radiatorcap Q op until the unit has completely cooled The i W possibility of hot coolant exists which Q 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 11 for engine radiator and recovery tank coolant capacities Make sure the coolant level in the recovery tank is always between the H and the L markings Table 11 Coolant Capacity 4 8 Gal 18 liters 2 Quarts 1 9 liters Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 12 has been added Engine and Radiator Reserve Tank Table 12 Anti Freeze Operating Temperatures Freezing Point Vol Anti Freeze When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Perio
9. the easier it is for water to condense This can be reduced by keeping the tank full with diesel fuel PAGE 40 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ MAINTENANCE 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 VOLVO Engine Manual for details 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 oil level must be between the two notches on the dipstick as shown in Figure 31 Replacing Oil Filter Remove the old oil filter e Apply a film of oil to the gasket on the new oil filter e Install the new oil filter e 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 Cleaning the Fuel Strainer Clean the fuel strainer if it contains dust or water Remove dust or water in the strainer cap and wash it in gasoline Securely fast
10. 00 d Specialorderitems e Electrical components f Paint chemicals and lubricants g Decalsandpaper products h 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 re turned to the sender at his expense 9 Crediton 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 spe cific date and all orders received on or afterthat date willbe billed atthe revised price Rebates for price declines and added charges for price increases will notbe made for stock on hand at the time of any price change Multiquip reserves the right to quote and sell directto Governmentagencies 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 forspecial handling including
11. 04 18 06 PAGE 79 DCA 220SSVU RUBBER SEALS ASSY RUBBER SEALS ASSY PAGE 80 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 RUBBER SEALS ASSY NO PART NO 1 0229201300 2 0228901010 3 0228901200 4 0228901050 5 0228900600 6 0229200950 7 0228901230 8 0229201200 9 0228801070 10 0228800640 11 0228800680 12 0228100560 13 0228100370 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 QTY 4 4 4 3 2 1 2 1 2 1 1 2 2 DCA 220SSVU RUBBER SEALS ASSY REMARKS DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 81 DCA 220SSVU NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY ca 3 5 8 4 8 5 s 3 3 2 r PAGE 82 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY NO 1 1 1 2 1 3 PART NO M3552000103 M9520100304 M9520100603 M4550000012 M9520000104 M9520000204 M9520100004 M9520200104 M9520200303 M9522000504 M9500000004 M9500100004 M9503000004 M9503000103 M9503100004 M9510100004 M4550000103 M9520000004 M9520000504 M9520000704 M9520100404 M9520100503 M9500300004 M9500300104 M9510100403 M9503200004 M9500500004 M9500500104 M95102000
12. GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED DCA 220SSVU ENCLOSURE ASSY CONT PAGE 78 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT PART NO 0021806016 0030006000 M9110100204 M9116100004 0016908020 M9310000004 M4463100002 M4490600004 M9310000103 M1483600204 M4463200002 M4493500004 0016908020 M4453200002 0016908065 M4453000003 M4493400004 M4453000103 M4493400104 M4453000303 M4493400304 M4453000203 M4493400204 M4453300404 M4493100204 M4453300104 M4493300704 0207008000 M9113000002 M9113000102 0021806016 0030006000 M4453700004 0016906016 M9110100804 M9116100004 M9110100904 M9116100004 0019208020 0601850097 0027208025 M9310000004 M4483000002 0016910025 PART NAME MACHINE SCREW HEX NUT HINGE WASHER HEX HEAD BOLT BLIND PLUG ROOF PANEL ACOUSTIC SHEET BONNET CAP CHAIN ASSEMBLY ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT SPLASHER PANEL HEX HEAD BOLT SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT DOOR HANDLE DOOR HANDLE MACHINE SCREW HEX NUT GUTTER HEX HEAD BOLT HINGE WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW BLIND PLUG SUPPORT LEG HEX HEAD BOLT REMARKS DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0
13. KIT nearest phone or keep a phone on the job site in case of emergencies ALWAYS have easy access to the phone numbers of the nearest Ambulance Doctor and Fire Department This information will be invaluable in the case of an emergency rM Emergencies ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest and first aid kit ALWAYS know the location of the Esas zz DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 13 DCA 220SSVU 50 HZ GENERATOR DECALS The DCA 220SSVU 50 HZ generator is equipped with a number of safety decals Figures 2 amp 3 These decals are provided for operator safety and maintenance information The illustration below and on the preceding page show the decals as they appear on the machine Should any of these decals become unreadable replacements can be obtained from your dealer OPERATING PROCEDURES Manual Starting nds Stopping 1 Check the engine oil coolant and fuel levels Place the Generator Circuit Breakers in the OFF position Replenish if necessary Set the Engine speed switch to the LOW position and allow 2 Place all Generator Circuit Breakers in the OFF position the unit to cool for a few minutes and close all doo 3 Turn the Auto OffiReset Manual switch to the OffiReset 3 Check that the Voltage select the Voltage
14. N 0602041275 1 3 V477556 FILTER OIL CARTRIDGE BI 55 1 REPLACES P N 0602041276 1 4 V3825133 CARTRIDGE FUEL FILTER REPLACES P N 0602042560 1 5 M4326200004 BREATHER PIPE 1 2 M4303200004 ENGINE FOOT 2 3 0012112040 HEX HEAD BOLT 8 4 0030012000 SPRING WASHER 8 5 0605000011 RUBBER SUSPENSION 2 6 0030016000 HEX NUT 4 7 0040016000 SPRING WASHER 4 8 0017112035 HEX HEAD BOLT 4 9 0030012000 4 10 0040012000 SPRING WASHER 4 11 0041212000 PLAIN WASHER 4 12 M4310200004 BRACKET RADIATOR 2 13 M4310200104 BRACKET RADIATOR 2 14 0016908020 HEX HEAD BOLT 4 15 0016910025 HEX HEAD BOLT 4 16 0602022566 ADAPTER 1 17 0602022561 90 DEG ELBOW 1 18 0603306590 CONNECTOR 1 19 0603300285 LOCKNUT 1 20 0605511395 VALVE 1 21 0603306395 HOSE JOINT 1 22 0602021070 CAP 1 23 0269200550 DRAIN HOSE 1 24 M4323500004 ADAPTER 1 20 0602012340 PACKING 1 26 0603306397 LONG NIPPLE 1 27 0603306497 90 DEG ELBOW 1 28 0605511397 VALVE 1 29 0602022991 HOSE JOINT 1 30 0191300750 DRAIN HOSE 1 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 65 DCA 220SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY D x We nn 2 III LAN ee PAGE 66 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 ENGINE AND RADIATOR ASSY NO PART NO PART NAME 31 0605515109 HOSE BAN
15. TO RETAIN NUT BOLT ASSEMBLY SHACKLE BOLT SHACKLE BOLT SPRING EYE BOLT DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 45 DCA 220SSVU 50 HZ TRAILER MAINTENANCE Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 61 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 17 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 17 Tire Torque Requirements First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 5 LUG NUTS 8 LUG NUTS LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 61 Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts PAGE 46 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ TRAILER WIRING DIAGRAM TOWING VEHICLE SIDE TRAILER SIDE DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT UTEM WHITE SINGLE Te YELLOW BROWN ES gt n GREEN STOP amp TURN LEFT LIC
16. bus shipments insured parcel postorin cases where Multiquip must personally deliverthe parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damagesin excess of the purchase price of the itemwith respectto which damagesare claimed andinno eventshall Multiquip be liableforloss 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 noras to any engine not manufac tured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of war ranty packaged with such units and Multiquip neither assumes notauthorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apartfrom such written statement of warranty there are no warranties express implied or statutory which extend beyond the description ofthe products on the face hereof PAGE 84 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 NOTE PAGE DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 85 OPERATION AND PARTS MANUAL HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson
17. change over position board is present at desired voltage In case of generator having multiple voltage ratings Auto Starting Stopping 4 Set the E d switch to the LOW position 5 Tum the switch to PYP I With the Auto Manual switch in the Auto position the Auto position to start the engine If the engine fails to start in the StartingiStopping controller monitors remote start contacts impos Indicate e contacta are opened Erik na ai or running and the Auto eset Manual switch must be returned to the OfffReset position before preceding the engine will stop All funcitons fo the Automatic shutdown 6 When th dy for starting d Id System work as in Manual Starting stopping A For cold weather conditions utilize the water heater until water button for approximately 30 seconds Start engine is warm If the engine still does not start please operate as in using the Auto OffiReset Manual switch to the Manual Starting Manual position As soon as the engine starts A release the button Emergency Stopping If the engine still does not start utilize the water heater 1 Place the Generator Circuit Breakers inthe OFF position until water is warm additional water heater is supplied 2 Turn the Auto OffiReset Manual switch to the OffiReset 7 After starting allow the engine to
18. on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain ALWAYS attach trailer s safety chains to towing vehicle properly ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly M DOT Requirements include the following amp 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 M Place chock blocks underneath wheel to prevent rolling while parked M Use the trailers swivel jack to adjust the trailer height to a level position while parked Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp turns Trailer should be adjusted to a level position at all times when towing Raise and lock trailer wheel stand in up position when transporting 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 Place support blocks underneath the trailers bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank AS AN FIRST AID
19. or fire could result causing severe bodily harm or even death NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator 8 HighTemperatures Allow the engine to cool before performing service and maintenance functions Contact with hot components can cause serious burns sav Idm 8 The engine of this generator requires an adequate free flow of cooling air NEVER operate the generator in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas DO NOT place hands or fingers inside generator engine compartment when engine is running NEVER run engine without air filter Severe engine damage may occur DO NOT leave the generator running in the manual mode unattended Refer to the VOLVO Engine Owner s Manual for engine technical questions or information 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 PAGE 10 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ RULES FOR SAFE OPERATION Generator Grounding To guard against electrical shock and possible damage to the equipment it is importa
20. 000002 TA M4493000004 2 M1413400004 3 0016908020 4 M4423000102 4A M4493100103 5 M4423000002 DA M4493100103 6 0016908020 7 0016910030 8 M4423200004 4495100004 9 0016908020 10 44 23200103 11 0016908020 12 M4433000002 13 0010114050 13A 0030014000 13B 0040014000 130 0041214000 14 0010120050 14A 0030020000 148 0040020000 14C 0041220000 15 M4443000002 15A 4493300104 16 0016910030 17 M4443300103 17A 4493300204 18 M4443300003 18A 4493300004 19 0207008000 20 0016908020 21 M4443200003 22 M4443600004 23 0207306000 23A 0041206000 24 M9113000002 DCA 220SSVU ENCLOSURE ASSY PART NAME BASE ACOUSTIC SHEET 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 OVER COVER FRONT FRAME HEX HEAD BOLT CENTER FRAME HEX HEAD BOLT HEX NUT SPRING WASHER PLAIN WASHER HEX HEAD BOLT HEX NUT SPRING WASHER PLAIN WASHER REAR FRAME ACOUSTIC SHEET HEX HEAD BOLT COVER REAR FRAME ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT HEX HEAD BOLT DOOR REAR FRAME WINDOW PLATE HEX NUT PLAIN WASHER DOOR HANDLE DD REMARKS DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 77 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO
21. 02 0600500090 0021106016 M4560100003 M4560100103 M4560100204 M4560100303 M4560100404 M4560100503 M4560100603 PART NAME OTY REMARKS DECAL OPERATING PROCEDURES sn M35200010 DECAL SAFETY INSTRUCTIONS ukasa M92010030 DECAL CAUTION u LP M92010060 CONTROL PANEL amp BOX GROUP DECAL CONTROL PANEL aaa M45000001 PLATE AMMETER CHANGE OVER SWITCH pem M92000010 PLATE VOLTMETER CHANGE OVER SWITCH M92000020 DECAL WARNING ELECTRIC SHOCK HAZARD M92010000 DECAL OVER CURRENT RELAY M92020010 DECAL SETTING FOR OUTPUT VOLTAGE boss M92020030 DECAL CIRCUIT BREAKER awaqa M92200050 ENGINE amp RADIATOR GROUP DECAL OIEDHAINPEUQ u uu ras _ M90000000 je em M90010000 DECAL WARNING MOVING PARTS 90300000 DECAL WATER OIL CHECK ber M90300010 DECAL WARNING HOT COOLANT gm M90310000 DECAL CAUTION HOT PARTS 91010000 OUTPUT TERMINAL GROUP DECAL RECEPTACLE amp CIRCUIT BREAKER M45000010 GROUN M92000000 DECAL START CONTACT M92000050 DECAL 3 PHASE OUTPUT TERMIN
22. 0601842450 VOLTAGE DIVIDER 1 28 M4246 700204 WIRE HARNESS GENERATOR 1 29 M435 7200032 WIRE HARNESS ENGINE 1 30 0601802149 FUSE 10A 1 31 0601802126 FUSE 8A 1 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 59 CONTROL BOX ASSY gt a DCA gt lt S gt Lu cc lt lt lt o lt lt lt lt lt cc LLI M m c D gt 9 O cN gt lt O lt gt co LLI lt a CONTROL BOX ASSY CONTROL BOX ASSY NO PART NO 1 M4213000012 2 0601809690 3 0027106016 4 0601870420 5 0601815168 6 M421360024 7 0016908035 8 M4273000003 9 M4276400004 10 0017106025 11 M4276200004 12 M4276300004 13 M9220100104 14 M9220100104 15 0040010000 16 0041410000 17 0016900030 18 0601820625 19 0027105016 20 0601820845 21 0601820846 22 0027104016 22A 0207004000 23 M4260600214 24 0016908020 20 0602202568 26 0027105016 27 0601821370 28 0027104020 29 V1622515 30 0027105035 DCA 220SSVU CONTROL BOX ASSY Q PART NAME CONTROL BOX CURRENT TRANSFORMER MACHINE SCREW CIRCUIT BREAKER 600A REAR CONNECTOR KIT SET PANEL CIRCUIT BREAKER HEX HEAD BOLT TERMINAL BOARD VOLTAGE CHANGE OVER CHANGE TERMINAL HEX HEAD BOLT TERMINAL PLATE CHANGE OVER PLATE TIE BOLT TIE BOLT SPRING WASHER PLAIN WASHER HEX HEAD BOLT AUTOMATIC VOLTAGE REGULATOR
23. 1 Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure 2 Place the engine speed switch Figure 54 in the HIGH position A HIGH UP Figure 54 Engine Speed Switch High 3 Placethe MPEC Control Switch Figure 55 in the AUTO position lt AUTO c MANUAL OFF RESET Figure 55 MPEC Control Switch AUTO 4 Continue operating the generator as s outlined in the Manual Start up procedure start at step 5 PAGE 38 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERATOR SHUT DOWN PROCEDURES 10511111 46114 0 Emergency Shutdown Procedure 1 shut down the engine in the event of an emergency switch the MAIN GFCI and LOAD Figure 38 circuit NEVER stop the engine suddenly except in an emergency Normal Shutdown Procedure breakers to OFF position To shutdown the generator use the following procedure 2 Place the MPEC Contr ol Switch switch Figure 57 to the OFF RESET position 1 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 38 to the OFF position 2 Place the engine speed switch Figure 56 in the LOW down position LOW DOWN Figure 56 Engine Speed Switch Low 3 Let the engine cool by running it at low speed for 3 5 minutes with no load applied 4 Place the MPEC Control Switch Figure 57 to the OFF RESET position AUTO MANUAL OF
24. 3650 mm 4074 1085 mm 68 89 in 1750 mm 39 17 in 995 mm 51 18 in 1 300 mm 40 74 in 1 035 mm 39 17 in 995 mm Figure 1 Dimensions DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 7 DCA 220SSVU 50 HZ SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS 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 This Owner s Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ Power Model DCA 220SSVU 50 Hz Whisperwatt Generator Before using this generator ensure that the operatin individual has read and understands all instructions in this manual SAFETY MESSAGE ALERT SYMBOLS The three 3 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 three words DANGER WARNING or CAUTION You WILL be KILLED or SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions HAZARD SYMBOLS Potential hazards associated with the operation of this equipmen
25. 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 the towing vehicle Application Indicates which units can be employed on a particular trailer DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 43 DCA 220SSVU 50 HZ 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 f driving over rough terrain inspect the brakes more frequently Figure 59 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 14 as listed below Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the wheel and drum for free rotation 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
26. AL g M92000070 DECAL DANGER HIGH V0CLI CC gne M92010040 DECAL WARNING uuu yu uuu us basen M92010050 BATTERY GROUP gt gt M90030000 DE GAL Pest M90030010 DECAL 91010040 MUFFLER GROUP DECAL WARNING ENGINE EXHAUST 90320000 FUEL TANK GROUP DECAL DIESELRUE luopumassa tet 12 24 44 90050000 DECAL FUEL ee M90050010 BONNET GROUP EE 91020000 2 MACHINE SCREW 4 STRIPE 1 STRIPE 1 STRIPE 2 STRIPE 1 STRIPE 2 STRIPE 1 STRIPE 1 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 83 Effective October 1 2002 TERMS AND CONDITIONS OF SALE PARTS PAYMENTTERMS Terms of payment for parts are net 10 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 asigned manifest has been obtained from the carrier and any claim for shortage or damage mustbe settled between the consignee andthe 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 willbe accepted and cred
27. AL SYSTEM HAZARDS Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch When 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 When the generator is set in the AUTO mode the generator will automically start in the event of comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch When running gthe generatori 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 A CAUTION ENGINE SPEED SWITCH 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 When the MPEC Control 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
28. ATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ SAFETY MESSAGE ALERT SYMBOLS AX WARNING ROTATING PARTS CAUTION RESPIRATORY HAZARDS NEVER operate equipment with covers or guards removed Keep fingers hands ALWAYS wear approved respiratory A hair and clothing away from all moving protection parts to prevent injury Ah CAUTION ACCIDENTAL STARTING Ah CAUTION SIGHT AND HEARING HAZARDS the ignition key when the pump is not in hearing protection OFF ALWAYS place the Engine ON OFF switch in the OFF position and remove Bee ALWAYS wear approved eye ano use CAUTION OVER SPEED CONDITIONS AX CAUTION EQUIPMENT DAMAGE MESSAGES NEVER tamper with the factory settings Other important messages are provided throughout this of the engine governor or settings manual to help prevent damage to your generator other Personal injury and damage to the engine property or the surrounding environment or equipment can result if operating in speed ranges above maximum allowable This generator other property or the surrounding environment could be damaged if you do not follow instructions DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 9 DCA 220SSVU 50 HZ RULES FOR SAFE OPERATION AX DANGER READTHIS MANUAL Failure to follow instructions in this manual may lead to serious injury or even DEATH This equipme
29. BOLT QTY A A F gt O O ODP ODP REMARKS DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 69 DCA 220SSVU BATTERY ASSY BATTERY ASSY PAGE 70 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU BATTERY ASSY BATTERY ASSY NO PARTNO PART NAME QTY REMARKS 1 0602220196 BATTERY 2 2 M9310500404 BATTERY SHEET 2 3 M9103000504 BATTERY BAND 2 4 0602220921 BATTERY BOLT SET 4 5 0040006000 SPRING WASHER 4 6 M4346900114 BATTERY CABLE 1 7 M4346400314 BATTERY CABLE 1 8 M4346900014 BATTERY CABLE 1 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 71 DCA 220SSVU MUFFLER ASSY MUFFLER ASSY PAGE 72 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU MUFFLER ASSY MUFFLER ASSY NO PARTNO PART NAME QTY REMARKS 1 M4330100002 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M4333000003 EXHAUST PIPE 1 4 V424628 GASKET 1 REPLACES P N 0602320196 5 M4333200004 GASKET 1 6 0017112055 HEX HEAD BOLT 4 7 M4330300004 COVER 2 8 0016908020 HEX HEAD BOLT 4 9 M4333300004 BRACKET 1 10 0016908020 HEX HEAD BOLT 4 11 0602326062 U BOLT SET 1 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 73 DCA 220SSVU FUEL TANK ASSY F
30. D 32 0269401700 BLOWBY HOSE 33 0605515199 HOSE BAND 34 M4483600003 HOSE GUIDE 35 0016908020 HEAD BOLT 36 M4303200104 COVER 37 0193601700 OVER FLOW HOSE 40 V9146844 V BELT ALTERNATOR 41 V873771 ALTERNATOR 12 VOLT 42 V3183909 COOLANT PUMP 43 V469982 SEAL RING SET COOLANT PUMP 44 V471629 SEAL RING COOLANT PUMP 45 V925095 O RING COOLANT PUMP 46 V1661993 THERMOSTAT 47 V471788 SEALING RING THERMOSTAT UPPER 48 V1544710 SEALING RING THERMOSTAT LOWER 49 V925092 O RING THERMOSTAT HOUSING 50 V843869 FAN RADIATOR 50 3827492 FAN RADIATOR 51 V966846 V BELT SET M IM 51 V966847 V BELT SET MAIN 52 V866095 CAP RADIATOR 53 V3827051 HOSE RADIATOR UPPER 54 V847307 STARTER MOTOR STANDARD 55 V848829 SENSOR TEMPERATURE 56 V11998 GASKET 57 V862154 SWITCH TEMPERATURE SENSOR 08 V866835 SENSOR OIL PRESSURE 59 V863169 MONITOR OIL PRESSURE 60 V3825133 FILTER FUEL 61 V3827052 HOSE RADIATOR LOWER 62 V3827338 RADIATOR DCA 220SSVU ENGINE AND RADIATOR ASSY A A 4 4 oL cl a REMARKS S N 2071145377 AND BELOW S N 2071145378 AND ABOVE S N 2071145377 AND BELOW S N 2071145378 AND ABOVE S N 2071145378 AND ABOVE DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 67 DCA 220SSVU OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASS
31. EL BLACK RED BLUE WHITE GREEN CIRCUIT BREAKERS FOR GFCI RECEPTACLES CIRCUIT BREAKERS FOR CS 6369 TWIST LOCK RECEPTACLES 100 VAC 20 AMP 2 W pinni A RECEPTACLE ACCESS DOOR LIFT TO OPEN CIRCUIT BREAKER PANEL 5 6369 TWIST LOCK AUX POWER RECEPTACLES 100 200V 50 AMPS Figure 8 Output Terminal Panel PAGE 24 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ OUTPUT TERMINAL PANEL FAMILIARIZATION 100 VAC GFCI Receptacles There are two 100 VAC 20 amp GFCI Duplex Nema 5 20R recepacles provided on the output terminal panel These receptacles can be accessed in any voltage selector switch position 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 9 in the center of the receptacle will check the GFCI function Both receptacles should be tested at least once a month 100 VAC 1 RESET BUTTON TEST BUTTON Figure 9 G F C I Receptacle Twist Lock Dual Voltage 100 200 VAC Receptacles There are three 100 200V 50 amp auxilliary twist lock CS 6369 recepacles Figure 10 provided
32. ENSE TAIL LIGHT i DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT l TAIL LIGHT i I I 1 1 1 DOUBLE FILAMENT BULB CONNECT I TO CHASSIS RIGHT GROUND yon TAIL LIGHT WHITE qm SINGLE AEK FILAMENT En Ten ELLOW WHITE COMMON GROUND BLUE TURN RIGHT GREEN TAIL amp LICENSE YELLOW STOP RED TURN LEFT LICENSE TAIL LIGHT DOUBLE FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR CONNECTOR LEFT TAIL LIGHT 4 Figure 62 Trailer Towing Vehicle Wiring Diagram DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 47 DCA 220SSVU 50 HZ GENERATOR WIRING DIAGRAM CONTROL BOX CONTROL PANEL 98 2 Gane Wing boron f m Wi LE Y zo E UJ 2 C LA I FF N A gt pe m A 7 LI A B K D 12111 122 213 m CN2 k P1 P2 m s J 2 3 CN3 Ulv w 1 2 3 3 2 1 Ulv IM T1 s1 R1 1 2 W L CN4 AVR CONNECTOR CONNECTOR VIEW FROM INSERTING WIRE SIDE VIEW FROM INSERTING WIRE SIDE Voltage Change Over Voltage Change Over Board 240V Set Board 280V Set Figure 63 Generator Wiring Diagram PAGE 48 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 30191094 5 Saa Bo 3 CI at ai ou w
33. F RESET Figure 57 MPEC Control Switch Off Reset 5 Verify that the all status LED on the MPEC display 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 occured during operation DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 39 DCA 220SSVU 50 HZ MAINTENANCE TABLE 13 INSPECTION MAINTENANCE 10 Hrs DAILY 250 Hrs 500 Hrs 1000 Hrs Check Engine Fuidteves KT Check Batery acate TT I x Check Fan Bet Condon f x PP Oreck reais pq Check for Loosening of x 1 Replace Engine x Qena Check Fuel FiterWatr Seperator Bow x L tt 11 Change Fuel Fiter Change Fuel Fiter Filter Clean Radiator and Check Coolant Protection Level Replace Air Filter Element 3 Measure Insulation Resistance Over 3M ohms 1 GENERATOR 1 Replace engine oil anf filter at 100 hours first time only 2 Add Supplemental Coolant Addatives SCA S to recharge the engine coolant 3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm 25 in H 0 4 f blowby hose needs to be replaced ensure that the slope of the bloby hose is at least a 1 2 inch per foot with no sags or dips that could collect moisture and or oil General Inspection
34. L FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Ouput Terminal Lugs or the convienience receptacles Figure 13 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 A e GFCI RECEPTACLE GROUND LOAD NEUTRAL Figure 13 Connecting Loads Over Current Relay An over current relay Figure 14 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 cur rent relay must be pressed The over current relay is lo cated in the control box Figure 14 Over Current Relay PAGE 26 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ 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 watta
35. MACHINE SCREW OVER CURRENT RELAY LR2D1308 OVER CURRENT RELAY LA7D1064 MACHINE SCREW HEX NUT SET PANEL ELECTRIC PARTS HEX HEAD BOLT SPEED CONTROL UNIT MACHINE SCREW HEGTIEIEB u MACHINE SCREW COOLANT LEVEL SWITCH MACHINE SCREW O O Mw gt BR ND A PD TY REMARKS REPLACES P N 0601823240 REPLACES P N 0602202569 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 61 lt O 2 gt lt gt lt O O a m lt O O 220SSVU DCA gt lt S gt Lu cc lt lt lt o lt lt lt lt lt cc LLI M m c D gt 9 O cN gt lt O CN co LLI lt a CONTROL BOX ASSY CONT DCA 220SSVU CONTROL BOX ASSY CONT CONTROL BOX ASSY CONT NO PARTNO PART NAME QTY REMARKS 31 LY2DUS24VDC RELAY REPLACES P N 0601827655 31A 0601823109 RELAY BASE PTF08A E 1 31B 0601824400 RELAY CLIP PYCA1 2 32 0601822060 TIMER RELAY H3Y 2 DC24V 10SEC 1 32A 0601823143 RELAY BASE PYF08A 1 32B 0601824404 RELAY CLIP Y92H 3 2 33 0601827684 RELAY AHE1232 DC24V 1 34 0027104020 MACHINE SCREW 6 35 M4213600104 STOPPER CONTROL PANEL 1 36 0041206000 PLAIN WASHER 1 3 0605010502 SNAP PIN 1 38 M4213500004 COVER CONT
36. OPERATION AND PARTS MANUAL POWER WHISPERWATT SERIES MODEL DCA 220SSVU 50 Hz GENERATOR PARTS LIST NO M4870300024A Revision 0 04 18 06 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES CALIFORNIA Proposition 65 Warnin 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 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING MQ POWER CORPORATE OFFICE 18910 Wilmington Ave 800 421 1244 Carson CA 90746 FAX 310 632 2656 Email mqpower O multiquip com Internet www mqpower com PARTS DEPARTMENT 800 427 1244 FAX 800 672 7877 310 537 3700 FAX 310 637 3284 SERVICE DEPARTMENT 800 835 2551 FAX 310 638 8046 310 537 3700 TECHNICAL ASSISTANCE 800 835 2551 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 EXT 279 FAX 310 638 8046 310 537 3700 EXT 279 COPYRIGHT 2006 MULTIQUIP INC MQ Power Inc Ultra Silent series 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 thier 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 w
37. OR CONTROL PANEL Figure 6 Generator Control Panel The definitions below describe the controls and functions of the DCA 220SSVU 50 HZ Generator Control Panel Figure 6 1 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 2 ACAmmeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 3 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 4 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 5 AC Voltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs 6 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 7 Main Circuit Breaker This three pole 600A main breaker is provided to protect the the U V and W Output Terminal Lugs from overload Located behind the generator control panel is the Generator Control Box This box contains some of the necessary electronic components required to make the generator function The Control Box is equipped with the following major components Over Current Re
38. OVER BEARING GASKET BEARING HEX HEAD BOLT SPRING WASHER PLAIN WASHER SUCTION COVER HEX HEAD BOLT HEX HEAD BOLT SPRING WASHER COVER FAN HEX HEAD BOLT PLAIN WASHER NUT RUBBER SUSPENSION HEX NUT SPRING WASHER BEARING 6907ZZ REMARKS DCA 220SSVU CONTROL PANEL ASSY CONTROL PANEL ASSY PAGE 58 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU CONTROL PANEL ASSY CONTROL PANEL ASSY NO PARTNO PART NAME QTY REMARKS 1 M4223000013 CONTROL PANEL 1 2 M4223000203 CONTROL PANEL 1 3 0605011211 PIN 2 4 0016908035 HEX HEAD BOLT 4 5 0601807642 FREQUENCY METER 45 65 HZ 240V 1 6 0601808992 AC AMMETER O 800A 1 7 0601801040 CHANGE OVER SWITCH AMMETER 1 8 0601800275 AC VOLTMETER O 600V 1 9 0601801041 CHANGE OVER SWITCH VOLTMETER 1 10 0601840073 RHEOSTAT VR 2W 1K OHM 1 11 0601840121 KNOB 1 12 ECU9988N220V CONTROLLER ECU uuu si uu tps kanne REPLAGES P N 0602202545 13 0601831340 SWITCH 1 14 0027104035 MACHINE SCREW 2 14A 0207004000 HEX NUT 2 15 0601831395 ENGINE SPEED SWITCH 1 16 0601831585 PREHEAT BUTTON 1 17 0601831586 CAP 1 18 0602120096 TACHOMETER 1 19 0602122098 OIL PRESSEUR GAUGE 1 20 0602123096 WATER TEMPERATURE GAUGE 1 21 0602121080 CHARGING AMMETER 1 22 0602125091 FUEL GAUGE 1 23 0602103090 ALARM LAMP 1 24 0601810120 PANEL LIGHT 1 20 0601831330 SWITCH PANEL LIGHT 1 26 M9220100004 SET SCREW 2 26A 0080200007 SNAP RING 2 27
39. PLATE HEX HEAD BOLT SPRING WASHER BALANCING WEIGHT KIT BEARING FLANGE BEARING 6314DDU C3 COUPLING RING HEX HEAD BOLT SPRING WSHER HEX HEAD BOLT SPRING WASHER STATOR ASSEMBLY RUBBER SEAL CLAMPER RUBBER SEAL CLAMPER RUBBER SEAL HEX HEAD BOLT PLAIN WASHER COVER RUBBER SEAL RUBBER SEAL HEX HEAD BOLT GROMMET END BRACKET FIELD ASSEMBLY EXCITER QTY REMARKS 1 1 1 1 2 2 2 1 9 1 1 8 8 1 1 1 1 8 8 8 8 1 1 1 1 1 1 2 2 1 1 1 6 1 1 1 INCLUDES ITEMS W PURCHASE ITEM 1 11 AS A SET INCLUDES ITEMS W DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 55 DCA 220SSVU 50 HZ GENERATOR ASSY CONT GENERATOR ASSY PAGE 56 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 GENERATOR ASSY 10 0012110065 10A 0042610000 108 0041210000 11 0017112045 12 1154400004 13 1154300004 14 0010106060 14 0040006000 148 0041206000 15 1154400103 16 0017106016 17 0343205150 18 0043605000 19 1132300114 20 0010106030 20A 0041206000 208 0600815000 21 0605000012 22 0030020000 22 0040020000 23 0070506907 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 57 DCA 220SSVU 50 HZ GENERATOR ASSY CONT PART NAME HEX HEAD BOLT SPRING WASHER PLAIN WASHER HEX HEAD BOLT C
40. 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 13 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual Air Cleaner Every 250 hours Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air Replace the air cleaner as needed Air Cleaner with Dust Indicator This indicator is attached to the air cleaner When the air cleaner element is clogged air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service After changing the air element press the dust indicator button to reset the indicator Service Daily If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exists Fuel Addition Add diesel fuel the grade may vary according to season and locations Removing Water from the Fuel Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally inspect the fuel tank for water contamination and drain the contents if required During cold weather the more empty volume inside the tank
41. R WATER SEPARATOR V466634 FILTER OIL CARTRIDGE nan V477556 FILTER OIL CARTRIDGE BI PASS panum V3827589 FILTER AIR ELEMENT 0601870420 CIRCUIT BREAKER 2 LY2DUS24VDC RELAY Part number on this Suggested Spare Parts list may supercede replace the P N shown in the text pages of this book DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 53 DCA 220SSVU 50 HZ GENERATOR ASSY GENERATOR ASSY PAGE 54 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 GENERATOR ASSY NO 1 1 1 1 23 1 9 1 4 1 4 1 24 7 33 1 44 7 5 7 6 7 7 7 8 7 9 7 10 7 11 7 12 PART NO C1110000002 0601842334 0601823282 0018205020 0040005000 0041205000 8171070002 8171611003 C1164200004 8171015003 012116045 0042616000 0601000209 C1112500004 0071906314 M4163400003 0343206120 0043606000 0012112040 0042512000 C1130100103 0226100420 8171323004 0223300120 8171323103 0221200300 0010110035 0041210000 C1132200003 0226000510 0225000470 0017106016 0601850144 C1154999992 C1138000003 DCA 220SSVU 50 HZ GENERATOR ASSY PART NAME ROTOR ASSEMBLY FIELD ASSEMBLY RESISTOR 80W 100K OHM RECTIFIER RM50TC 24 HEX SOCKET HEAD CAP SCREW SPRING WASHER PLAIN WASHER FAN COUPLING DISK WASHER COUPLING HUB BALANCING
42. ROL BOX 1 39 0016908020 HEX HEAD BOLT 8 40 M4213300004 SIDE PANEL CONTROL BOX 1 41 0016908020 HEX HEAD BOLT 4 42 M4213400004 BACK PANEL CONTROL 80X 5 M TBD 42 M4213400014 BACK PANEL CONTROL 80X S N TBD 43 0016908020 HEX HEAD BOLT 8 44 0016910025 HEAD BOLT 4 45 0601842449 RESISTOR 3 75KW 150 OHM S N 8000001 8000019 45 0601842449 RESISTOR 5W 150 Verner S N 8000020 AND ABOVE 46 0027104010 MACHINE 5 S N 8000020 AND ABOVE DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 63 DCA 220SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY 1 1 NN e w v e MES QUPD MACH Qul Cim C is e s a N niet JN NA SRM NOU CS Cen gt CO NM uu ot 1 YO FE M PAGE 64 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY NO PARTNO PART NAME QTY REMARKS 1 M4386200004 ENGINE amp RAD SET TAD741GE INCLUDES ITEMS VV X 1 1 V3827589 ELEMENT AIR FILTER Lassen REPLAGES P N 0602046620 1 2 V466634 FILTER OIL CARTRIDGE EE REPLACES P
43. UEL TANK ASSY Ne 14 PAGE 74 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU FUEL TANK ASSY FUEL TANK ASSY 1 M4363000002 1 1 0605505070 2 M4363200004 3 M9310500104 4 0016908020 5 0207308000 6 0222100720 7 M9200000003 8 M9200200004 9 0150000018 10 0016906020 11 M1363400104 12 0605515198 13 V8159966 13 78159975 14 0602022567 15 0602022992 16 0016910030 17 0191302150 18 0191300600 19 0191302200 20 0605515109 PART NAME FUEL TANK CAP FUEL TANK TANK BAND SUPPORTER SHEET HEX HEAD BOLT HEX NUT RUBBER SHEET DRAIN JOINT DRAIN BOLT O RING HEX HEAD BOLT DRAIN HOSE HOSE BAND WATER SEPARATOR FILTER WATER SEPARATOR 90 DEGREE ELBOW SWIVEL JOINT HEX HEAD BOLT SUCTION HOSE SUCTION HOSE RETURN HOSE HOSE BAND O lt NAN A O REMARKS REPLACES P N 0602042265 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 75 DCA 220SSVU ENCLOSURE ASSY ENCLOSURE ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 76 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 ENCLOSURE ASSY 1 M4413
44. VER lubricate components or attempt service on a running machine ALWAYS disconnect the NEGATIVE battery terminal before performing service on the generator M Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator ALWAYS allow the machine a proper amount of time to cool before servicing Keep the machinery in proper running condition Fix damage to the machine immediately and always replace broken parts ALWAYS service air cleaner frequently to prevent engine malfunction AX WARNING BURN HAZARDS To prevent burns DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations Always allow sufficient time for the engine and generator to cool before performing ET maintenance Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to gush out of the radiator causing severe scalding to any persons in the general area of the generator Coolant Drain Plug Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug therefore causing severe scalding to any persons in the general area of the generator 8 Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug therefore causing severe scalding to an
45. Y ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 5 BLACK 2 WHITE 6 CATERPILLAR YELLOW 3 SPECTRUM GREY 7 CATO GOLD 4 SUNBELT GREEN 8 RED THE SERIAL NUMBER MAY BE REQUIRED PAGE 68 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 OUTPUT TERMINAL ASSY 1 M4230700003 2 M9220100304 3 M9220100404 4 0039316000 5 0040016000 6 0041416000 7 M4233200004 8 0016908040 9 0601815194 10 0027104016 11 0601850275 12 0603306775 13 0027104016 14 0601808803 15 0601808804 16 M4260600104 16 1 0222100150 17 0016906020 18 0601812598 19 0601812538 20 0027104016 20A 0207004000 21 M4236100103 22 0010112045 23 0041212000 24 M9310200104 20 0030012000 26 M9210000204 2 M4236100004 28 0017110040 29 M9116000004 30 M9310200004 31 M4236100204 32 0016908020 DCA 220SSVU OUTPUT TERMINAL ASSY PART NAME TERMINAL BOARD OUTPUT TERMINAL BOLT TIE BOLT HEX NUT SPRING WASHER PLAIN WASHER TERMINAL PLATE HEX HEAD BOLT TERMINAL BLOCK MACHINE SCREW GROMMET BLIND PLUG MACHINE SCREW CIRCUIT BREAKER SINGLE POLE 20A CIRCUIT BREAKER DOUPLE POLE 50A BRACKET CIRCUIT BREAKER RUBBER CUSHION HEX HEAD BOLT RECEPTACLE GFCI 20A RECEPTACLE CS6369 50A MACHINE SCREW HEX NUT TERMINAL COVER HEX HEAD BOLT PLAIN WASHER STAY RUBBER HEX NUT SPRING COVER HEX HEAD BOLT COLLAR STAY RUBBER TERMINAL COVER HEX HEAD
46. amp multiguip com 0118 81 1 3 10108 INTERNET www mgpower com DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 5 DCA 220SSVU 50 HZ SPECIFICATIONS Table 1 Generator Specifications DCA 220SSVU Tyne Revolving field self ventilated yp open protected type synchronous generator Armature Connection Star with Neutral Zig Zag Standby Output 220 KVA 176 KW Prime Output 200 KVA 160 KW Voltage 10 100 127 200 and 254V Voltage 30 200 220 400 and 440V Frequency 50 Hz Speed 1500 rpm Power Factor Dry Weight 7 678 lbs 3 483 kg 8 580 Ibs 3 892 kg Table 2 Engine Specifications VOLVO PENTA TAD741GE Type 4 cycle water cooled direct injection turbo charged No of Cylinders 6 cylinders Bore x Stroke 4 21 in x 5 31 in 107 mm x 135 mm Displacement 444 cu in 7 28 liters Electric 12VDC Coolant Capacity 9 8 gal 37 liters Lube Oil Capacity 7 7 gal 29 liters Fuel Type 2 Diesel Fuel Fuel Tank Capacity 100 gal 380 liters Fuel Consumption 10 1 gal 38 2 L hr at full load Battery 12V 225 AH x 2 PAGE 6 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ DIMENSIONS TOP SIDE AND FRONT TOP VIEW SIDE VIEW TABLE 3 DIMENSIONS rds Dimension ft mm Reference Letter Dimension ft mm 42 12 n 1070 mm 143 70 in
47. cabinet doors on the right side of the generator N from generator control panel position Remove fuel cap Ah WARNING RESPIRATORY HAZARDS and fil tank Figure 33 Diesel fuel and its vapors are dangerous i to your health and the surrounding environment Avoid skin contact and or dif inhaling fumes WHISPERWATT pas Figure 33 Fueling the Generator FUEL TANK 1 Level Tanks Make sure fuel cells are level with the FILLER PORT ground Failure to do so will cause fuel to spill from the tank before reaching full capacity Figure 32 DIESEL FUEL 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 3 NEVER overfill fuel tank It is important to read the c fuel gauge when filling trailer fuel tank DO NOT wait for Level Ground fuel to rise in filler neck Figure 34 Figure 32 Only Fill on Level Ground 2 ON CONTROL PANEL O ONLY use 2 diesel fuel when 25 refueling On OL ZZ ZZ ZZ OL Oh ON OL OF OL Of 01 Z Figure 34 Full Fuel Tank A CAUTION REFUELING THE GENERATOR DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 35 Fuel EXPANDS When Heated Figure 35 Fuel Expansion DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06
48. cal attention PAGE 12 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ RULES FOR SAFE OPERATION Towing amp Transporting Safety To reduce the possibility of an accident while transporting the generator on public roads always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of safety precautions should be followed when towing your generator A CAUTION FOLLOW TOWING REGULATIONS Check with your local county or state safety towing regulations in addition to meeting Department of Transportation DOT Safety Towing Regulations before towing your generator ALWAYS shutdown engine before transporting Tighten both fuel tank caps securely W f generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws Follow the listed Towing amp Transporting Safety guidelines for basic towing techniques 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 M 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
49. dically 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 it in accordance with the VOLVO 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 VOLVO Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 36 when depressed with the thumb as shown below 10 15 MM DEFLECTION NEVER place hands near the belts or fan while the generator set is running PAGE 34 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ PRE 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 starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with an approved battery terminal treatment compound Replace battery with only recommended type battery The batt
50. dirty Clean magnetic pick up DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 51 DCA 220SSVU 50 HZ 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 The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availibility of the parts listed Sample Parts List NO PART NO PART QTY REMARKS 1 12345 BOUT 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2k 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 HOSE indict A R MAKE LOCALLY 4 12349 BEARING 1 SIN 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol ft 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 are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine 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 Colum
51. e over board Figure 15 To obtain some of the voltages as listed in Table 6 see below will require a fine adjustment using the voltage regu lator VR control knob located on the control panel Table 8 Generator Ampere Ratings MED 30 Voltage Change Over Board The voltage change over board Figure 15 is located on the control box behind the generator control panel This board has been provided for ease of voltage selection JUMPER 6 PLACES Maximum Amps Table 9 shows the maximum amps the generator can pro Figure 15 Voltage Change Over Board vide DO NOT exceed the maximum amps as listed CAUTION CHANGING VOLTAGES Table 9 Generator Maximum Amps NEVER attempt to place jumper plates on the voltage change over board while the generator is in operation There exist the possibility of electrocution electrical shock or burn which cause severe bodily harm or even death Rated Voltage ___ 533 amps 4 wire Table 7 Voltages Available Three Phase 200V 220V 240V 416V 440V 266 amps 4 wire Single Phase 115V 127V 139V 240V 254 577 amps 288 amps PAGE 28 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERATOR OUTPUTS GAUGE READING How to Read the Output Terminal Gauge The AC ammeter and AC voltmeter change over switches on the control panel DO NOT effect the generator output They are provided to help observe how
52. en the fuel strainer cap so that fuel will not leak Check the fuel strainer every 200 hours of operation or once a month Replacing Fuel Filter e 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 o Vent any air Flushing Out Radiator and Replacing Coolant e 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 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 Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufaturer e Close radiator cap tightly Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or N steam Generator Storage For longe term storage of the generator the following is recommended o Fill the fuel tank completely Treat with a fuel stabilizer if necessary e Completely drain the oil from the crankcase and refill if necessary with fresh oil Clean the entire gene
53. erature Gauge The tachometer gauge Figure 51 will indicate the speed of the engine when the generator is operating Under normal operating conditions 254 this speed is approximately 1600 RPM s Figure 51 Engine Tachometer Gauge Place the main GFCI and aux circuit breakers in the ON position Figure 52 MAIN AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER soua INCREASE H Figure 47 Voltage Adjust Control Knob 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 48 Ammeter No Load Figure 49 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 44 to 73 psi 303 503 kPa When starting the genera Figure 49 Oil Pressure Gauge 13 Observe the generator s ammeter Figure 52 Main Aux and GFCI Circuit Breakers ON Figure 53 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 53 Ammeter Load 14 The generator will run until manually stopped or an abnormal condition occurs DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 37 DCA 220SSVU 50 HZ GENERATOR START UP PROCEDURE AUTO MODE Starting Auto Mode A DANGER ELECTRIC
54. ery type used in this generator is BCI Group 27 The battery 15 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 37 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 A CAUTION BATTERY SERVICING SAFETY ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST POSITIVE NEGATIVE BATTERY Figure 37 Battery Connections When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position ALWAYS make sure that the MPEC Control Switch 15 in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compound around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polari
55. following requirements m API Service Classification CC SC m API Service Classification CC SD m API Service Classification CC SE m API Service Classification CC SF Table 10 Recommended Motor Oil DCA 220SSVU 50 HZ PRE SETUP Fuel Check A DANGER EXPLOSION FIRE HAZARDS Fuel spillage on a hotengine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator Refilling the Fuel System A CAUTION REFUELING THE GENERATOR ONLY properly trained personel 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 31 ALWAYS fill the fuel tanks with clean fresh 2 diesel fuel DO NOT fill the fuel tanks beyond their Capacities Pay attention to the fuel tank capacity when replenishing fuel The fuel tank cap must be closed tightly after filling Handle fuel in a safety container If the container does not have a spout use a funnel Wipe up any spilled fuel immediately IC TRAILER MOUNTED FUEL TANK OPTION N ENVIRONMENTAL FUEL TANK OPTION Figure 31 Internal Fuel Tank System PAGE 32 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ PRE SETUP Refueling Procedure 3 Open
56. fore servicing M90300000 M90310000 M95 20100204 P N M9520100204 P N M9520100404 To use 50 amp receptacles adjust the voltage selector switch to the single phase position and the main line circuit breaker to the on position P N M1500020 P N M1550000204 A WARNING A CAUTION ELECTRIC SHOCK HAZARD HOT PARTS can burn skin e Do not touch output terminals while this 15 pu P N M9503000004 Do not touch until machine is operating the machine has e Turn power off before sufficiently cooled m91010000 servicing P N M9510100004 P N M9520100503 A WARNING ELECTRIC SHOCK HAZARD e Do not touch internal wiring or connections while this machine is operating e Turn power off before servicing AN CAUTION This machine stops and starts Automatically and without notice P N B15200010 M9201 0000 P N B15200010 P N M9520100004 Figure 3 Generator Decals Cont inued DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 15 DCA 220SSVU 50 HZ INSTALLATION GENERATOR GROUND LUG 502 GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND NZ GROUND CABLE 8 FT MINIMUM REFERENCE 250 830 Figure 4 Typical Generator Grounding Application PAGE 16 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ INSTALLATION Outdoor Installation I
57. ge than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment If wattage is not given on the equipments 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 single phase induction motors 0 4 0 75 Electric heaters incandescent 10 lamps Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication 10 equipment Table 6 Cable Selection 60 Hz Single Phase Operation Load In Watts Maximum Allowable Cable Length Current in Amperes At 100 At 200 Volts Volts as wo om toon coon zon eo 120 soon son coon n zs wo 1900 zen ian 1200 2400 250 ft 150 ft 100 ft 1800 3600 150 ft 100 ft 65 ft 2400 4800 125 ft 75 ft 50 ft 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 If 30 load kVA is not given on the equipment nameplate approximate 30 load output maybe determined by multiplying voltage by amperage by 1 732 Motors and motor driven equipment draw much greater current for star
58. 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 Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical NEC articles 250 64 b and 250 66 set the following grounding requirements 1 Use one of the following wire types to connect the generator to earth ground a Copper 10 AWG 5 3 mm or larger b Aluminum 8 AWG 8 4 mm or larger 2 When grounding the generator Figure 4 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies that the earth ground rod should be buried aminimum of 8 ft into the ground When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 17
59. he main G F C I and aux circuit breakers Figure 38 in the OFF position prior to starting the engine MAIN GFCI AUXILIARY CIRCUIT CIRCUIT CIRCUIT BREAKER BREAKER BREAKER Figure 38 Main Aux and GFCI Circuit Breakers OFF 2 Make sure the 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 13 These load connection points can be found on the output terminal panel and the output terminal panel s hard wire hookup panel 4 The output terminal lugs are protected by a plastic cover Remove this cover to gain access to the terminals Tighten terminal nuts securely to prevent load wires from slipping out 5 Close all engine enclosure doors Figure 39 CORRECT INCORRECT Figure 39 Engine Enclosure Doors Starting Manual 1 In cold weather conditions press and hold the pre heat button Figure 40 for at least 50 seconds to warm the engine glow plugs Figure 42 Pre Heat Button 2 Place the engine speed switch Figure 41 in the LOW down position w LOW DOWN Figure 41 Engine Speed Switch Low 3 Once the engine glow plugs have been warmed place the MPEC Control Switch in the MANUAL position to start the engine Figure 42 gt ano CD MANUAL OFF RESET Figure 42 MPEC Control Switch Manual Position 4 Once the engine starts let it engine run for 1 2 minutes
60. hen 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 4 Water Temperature Gauge During normal operation this gauge be should read between 165 203 F 5 Charging Ammeter Gauge Indicates the current being supplied by the engine s alternator which provides current for generator s control circuits and battery charging system 6 Fuel Gauge Indicates amount of diesel fuel available 7 Tachometer Indicates engine speed in 5 for 60 Hz operation This meter should indicate 1800 RPM s when the rated load is applied In addition a built in hour meter will record the number of operational hours that the generator has been in use 8 Engine Speed Switch This switch controls the speed of the engine low high 9 Pre Heat Button Press and hold this button for 50 seconds to warm cold weather the engine glow plugs 10 Coolant Alarm Lamp This lamp will illuminate when the coolant level falls below a safe operating level 11 Auto On Off Engine Controller MPEC This controller has a vertical row of status LED s inset that when lit indicate that an engine malfunction fault has been detected When a fault has been detected the engine auto controller will evaluate the fault and all major faults will shutdown basene the generator During cranking been cycle The MPEC will atte
61. ing of the output voltage is required PAGE 30 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ OUTPUT TERMINAL PANEL CONNECTIONS 30 440 UVWO Terminal Output Voltages as shown in Figure 26 This configuration uses 6 jumper plates in 3 different positions Remember there are 2 5 jumper plates at every position Every jumper plate must be used USE 2 JUMPER PLATES AT EACH POSITION Figure 26 Voltage Change Over Board 480V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 27 GROUND CONNECTION MUST BE USED AT ALL TIMES THREE PHASE 440 VAC LOAD CONNECTIONS Figure 27 UVWO Terminal Lugs 3 440V Connections 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 440V UVWO Terminal Output Voltages 1 Jumper the voltage change over board for 480V operation 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 26 Connect the load wires to the UVWO terminals as shown in Figure 28 GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 440 VAC LOAD CONNECTIONS Figure 28 UVWO Terminal Lugs 10 440V Connections 10 254 UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 26 Connect the l
62. it will be allowed subjectto the following provi sions 1 AhReturned Material Authorization must be approved by Multiquip prior to ship ment 2 ToobtainaReturn Material Authorization alist must be provided to Multiquip Parts Sales that defines item numbers quanti ties and descriptions of the items to be returned a Thepartsnumbers and descriptions must match the current parts price list b The list must be typed or computer generated The list must state the reason s for the return d The list must reference the sales order s orinvoice s under which the items were originally purchased e The list must include the name and phone number of the person request ingthe RMA Acopy ofthe Return Material Authoriza tionmustaccompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiguip s designated receiving point 5 Partsmustbeinnewandresalable con dition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 Thefollowingitems 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 andotherrubber parts that were pur chased morethan six months priorto the return date c Anylineitem with an extended dealer net price of less than 5
63. it breakers 20A Five output terminal lugs 32 power Battery Charger Optional Water Heater Optional Open Delta Excitation System The DCA 220SSVU 50 Hz generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When a heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connection of B to C This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands of the required load Engine The DCA 220SSVU 50 Hz is powered b
64. ith the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations are based on the DCA 220SSVU 50 Hz WHISPERWATT AC Generator Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations To find the latest revision of this publication visit our website at www mqpower com DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 3 DCA 220SSVU 50 HZ TABLE OF CONTENTS MG POWER DCA 220SSVU 50 Hz WHISPERWATT GENERATOR California Proposition 65 Warning 2 Here s How To Get 3 TEGENE aS 4 Parts Ordering Procedures 5 CC 6 Dimensions Top Side Front 7 Safety Message Alert Symbols 8 9 Rules for Safe Operation 10 13 aenerator Decals tbe mess 14 15 16 17 General Information a 18 Major Components 22 19 Generator Control Engine Operating
65. lay Voltage Rectifer AVR Starter Relay Current Transformer Voltage Selector Switch Three Phase Circuit Breaker Remember the overcurrent relay monitors the current flowing from the UV 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 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 21 DCA 220SSVU 50 HZ ENGINE OPERATING PANEL AUTO MANUAL OFF RESET O LOW OIL PRESSURE HIGH COOLANT TEMPERATURE O OVERCRANK O OVERSPEED ENGINE RUNNING Figure 7 Engine Operating Panel PAGE 22 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA 220SSVU 50 Hz Engine Operating Panel Figure T Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position 2 Panel Light Switch When activated will turn on control panel light 3 Oil Pressure Gauge During normal operation this gauge be should read between 44 to 73 psi 303 503 kPa W
66. mpt to crank the engine for 10 seconds before disengaging 4 O LOW OIL PRESSURE If the engine does not engage start by the third attempt the engine will be shutdown by the engine controllers Over Crank Protection mode li the engine engages at a speed RPM s that is not safe the controller will shutdown the engine by initializing the Over Speed Protection mode Also the engine controller will shut down the engine in the event of low oil pressure high coolant temperature low coolant level and loss of magnetic pickup These conditions can be observed by monitoring the LED status indicators on the front of the controller module A MPEC Control Switch This switch controls the running of the unit If this switch is set to the OFF RESET position the unit will not run When this switch is set to the MANUAL position the generator will start immediately If the generator is to be connected to a building s AC power source via a transfer switch isolation place the switch in the AUTO position In this position the generator will monitor the AC line output from the building s power source B Low Oil Pressure Indicates the engine pressure has fallen below 15 psi The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered a major fault High Coolant Temperature Indicates the engine temperature has exceeded 239 F The engine temperature is detec
67. much power is being supplied produced at the UVWO terminals lugs When the voltage change over board is jumpered for 30 240V operation See Figures 17 and18 place the AC Volt meter Change Over Switch See Figures 19 and 20 to the W U position and the AC Ammeter Change Over Switch Figure 19 to the U or W position to read the output on the selected leg JUMPER 6 PLACES Figure 16 Voltage Change Over Board 240V Configuration Figure 19 AC Ammeter V W U V OFF Figure 17 AC Voltmeter Figure 18 AC Voltmeter Gauge Change Over Switch Volt reading on W U Lug OFF Figure 20 AC Ammeter Change Over Switch Amp reading on U lug The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 29 DCA 220SSVU 50 HZ OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages DECREASE INCREASE Various output voltages can be obtained using the UVWO output terminal lugs The voltages at the terminals are de pendent 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 10 200 UVWO Terminal Output Voltages range of the output voltage and can be configured in two 1 Make sure the voltage change over board is jumpered different
68. n 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 time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiguip 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 Reguired 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 unigue symbol will be included when this item is purchased Indicated by INCLUDES ITEMS W unigue 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 SIN XXXX TO S 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 ona specific model or model number va
69. ng the trailer Typical braking systems are electric surge hy draulic hydraulic surge and air GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry in cluding the fuel cell empty Frame Length Measurement is from the ball hitch to 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 8 Coupler Type of hitch used on the trailer for towing 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 59 for lug nut tightening and sequence Axle Indicates the maximum weight the axle can sup port 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
70. nish or replace Trailer overloaded Correct weight ae p Brake drums scored or grooved Machine or replace One Side Tires unmatched on the same axle Match tires Brake components loose bent or broken Replace components Locking Brakes Brake drums out of round System lubricated Noisy Brakes Brake lining thickness incorrect or not Install new shoes and adjusted correctly linings Replace rubber parts 9 Enough brake fluid or correct fluid fill with dot 4 fluid Dragging Brakes PAGE 44 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ 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 A CAUTION EYESIGHT HAZARD ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury N T A A CAUTION REPAIRING TRAILER WHEELS DO NOT attempt to repair or modify a wheel DO NOT install in inner tube to correct a leak through the rim Ifthe rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and 227 Cause serious eye or bodily injury Tire Wear Inflation Tire inflation pressure is the most important factor in tire life Pressure should be checked c
71. nstall the generator in a area that is free of debris bystanders and overhead obstructions Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes The installation site must be relatively free from moisture and dust All electrical equipment should be protected from excessive moisture Failure to do will result in deterioration of the insulation and will result in short circuits and grounding Foreign materials such as dust sand lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts AX CAUTION EXHAUST HAZARD 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
72. nt is to be operated by trained and qualified personnel only This equipment is for industrial use only The following safety guidelines should always be used when operating the DCA 220SSVU 50 HZ Whisperwatt AC Generator General Safety DO NOT operate or service this SA equipment before reading this entire manual The operator MUST BE familiar with proper safety precautions and operations techniques before using generator M This equipment should not be operated by persons under 18 years of age NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by the job NEVER operate this equipment when not feeling well due to fatigue illness or taking medicine NEVER operate this equipment under the influence or drugs or alcohol NEVER use accessories or attachments which are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties Whenever necessary replace nameplate operation and safety decals when they become difficult read ALWAYS check the machine for loosened threads or bolts before starting NEVER operate the generator in an explosive atmosphere or near combustible materials An explosion
73. nt to provide a good EARTH ground Article 250 Grounding of the National Electrical Code NEC provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical The following safety recommendations should also be followed ALWAYS make sure generator is properly grounded NEVER use gas piping as an electrical ground ALWAYS make sure that electrical circuits are properly grounded 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 ALWAYS be sure to use the ground terminal green wire when connecting a load to the U V and W output terminal lugs Electrical Safety ALWAYS have a qualified electrician perform the generator wiring installation ALWAYS make sure generator installation is accordance with the National Electrical Code NEC and local codes before operating generator NEVER use a defective or frayed power cable Check the cable for cuts in the insulation NEVER use a extension cord that is frayed or damaged where the insulation has been cut ALWAYS make certain that proper extension cord has been selected for the job See Table 6 NEVER power cables or cords lay in water NEVER stand in water while AC power from the generator is being
74. oad wires to the UVWO terminals as shown in Figure 29 GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 204 VAC LOAD CONNECTIONS Figure 29 UVWO Terminal Lugs 10 254V Connections DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 31 Circuit Breakers To protect the generator from an overload a 3 pole 600 amp main circuit breaker is provided to protect the U V and W Output Terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 30 on the dipstick See Table 10 for proper selection of engine oil ADD FULL LIMIT Figure 30 Engine Oil Dipstick When checking the engine oil be sure to check if the oil is clean If the oil is not clean drain the oil by removing the oil drain plug and refill with the specified amount of oil as outlined in the Volvo Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the
75. 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 Hydraulic Surge Brakes Hydraulic surge brakes Figure 59 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 Spins Cylinder Backing Actuating Pin Plate 3 Hold Down Spring Primary Shoe Adjuster Spring Adjuster Assembly Figure 59 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 14 Hydraulic Brake Troubleshooting Symptom Possible Cause Solution Brake line broken or kinked Repair or replace Brake lining glazed Rebur
76. old 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 15 Tire Wear Troubleshooting will help pinpoint the Causes and solutions of tire wear problems TABLE 15 TIRE WEAR TROUBLESHOOTING Adjust pressure to Center Wear Over Inflation particular load per tire manufacturer Edge Wear Under Inflation Side Wear Loss of camber or overloading Adjust pressure to particular load per tire manufacturer Make sure load does not exceed axle rating Align wheels Cupping Out of balance Check bearing adjustment and balance tires Wheel lockup amp Avoid sudden stops when a tire skidding possible and adjust brakes Suspension The leaf suspension springs and associated components Figure 60 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 16 SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAM BOLTS LEAF SUSPENSION FRONT HANGER NUT FRONT BOLT HANGER BOLT LOCKING TIE PLATE Figure 60 Major Suspension Components Table 16 Suspension Torque Requirements jom SNUG FIT ONLY PARTS MUST ROTATE FREELY LOCKING NUTS OR COTTER PINS ARE PROVIDED
77. oller unit MPEC If the problem cannot be remedied consult our company s business office or service plant TABLE 19 ENGINE CONTROLLER TROUBLESHOOTING MPEC SYMPTOM POSSIBLE PROBLEM SOLUTION Low oil level Fill oil level Low oil pressure light is Oil pressure sending unit failure Replace oil pressure sending unit M Time delay malfuntion in Controller Refer to dealer Wire shorted Inspect repair wire Low coolant level Fill coolant level on Optionally Installed Sending unit failure Replace sending unit Low battery voltage Replace charge battery Fan belt tension incorrect Tighten replace fan belt Air flow is not circulation through radiator Clean repair radiator grill High coolant temperture Exhaust leaking Replace repair gaskets or faulty part light is on Generator being overloaded Check reduce load Thermostat failure Replace thermostat Air intake blocked Clear all air intakes Temperature switch failure Replace temperature switch No or low Fuel Fill fuel level Overcrank light is on Controller needs to be calibrated Refer to dealer RPM engine speed too high Adjust RPM Governor actuator needs to be adjusted Adjust governor actuator Overspeed light is on Governor controller needs to be adjusted Adjust governor controller Engine Controller needs to be calibrated Refer to dealer Loss of MPU light s or Magnetic pick up out of adjustment Adjust magnetic pick up xi Magnetic pick up
78. on the output terminal panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position 5 6369 TWIST LOCK RECEPTACLES SINGLE PHASE 100 200 VAC 50 AMP OUTPUT Figure 10 100 200V Twist Lock Auxiliary Receptacles Each auxilliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on all three receptacles is dependent on the load requirements of the Output Terminal Lugs Turn the voltage regulator control knob Figure 11 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 EN Figure 11 Voltage Regulator Control Knob Removing the Plastic Face Plate Hard Wire Hookup Panel The Output Terminal Lugs are protected by a plastic face plate cover Figure 12 Un screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure After the load wires have been securely attached to the terminal lugs reinstall the plastic face plate HARD WIRE HOOKUP PANEL PLASTIC TERMINAL COVER SECURING BOLTS Figure 12 Plastic Face Plate Output Terminal Lugs DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 25 DCA 220SSVU 50 HZ OUTPUT TERMINAL PANE
79. positions that provide 6 different output voltages at for 240V operation as shown in Figure 21 the UVWO output terminals The generator is shipped from the factory in the 200V configuration The voltage regulator VR allows the user to increase or decrease the selected voltage 30 220 UVWO Terminal Output Voltages 1 Jumperthe voltage change over board for 240V operation as shown in Figure 21 Figure 23 Voltage Regulator Knob 2 Connecttheload wires to the UVWO terminals as shown in Figure 24 JUMPER 8 PLACES GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 200 VAC LOAD CONNECTIONS Figure 24 UVWO Terminal Lugs 10 200V Connections Figure 21 Voltage Change Over Board 240V Configuration 10 127 UVWO Terminal Output Voltages 1 sure the voltage change over board is jumpered for 240V operation as shown in Figure 21 2 Connect the load wires to the UVWO terminals as shown in Figure 25 2 Connect the load wires to the UVWO terminals as shown in Figure 22 GROUND CONNECTION MUST BE USED THREE PHASE AT ALL TIMES 220 VAC LOAD CONNECTIONS GROUND Figure 22 UVWO Terminal Lugs Ter USER 3 220V Connections ETP AT ALL TIMES 3 Turn the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to Figure 25 UVWO Terminal Lugs decrease voltage output Use voltage regulator 19 127V Connections adjustment knob whenever fine tun
80. rator internal and external Cover the generating set and store in a clean dry place Disconnect the battery Make sure engine coolant is at proper level If generator is mounted on a trailer jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 41 DCA 220SSVU 50 HZ 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 If the generator will be used daily the battery should normally not requi
81. re 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 an power cord of adequate size To ensure adequate starting capability always have power applied to the generator s internal battery charger OUTPUT TERMINAL BATTERY CHARGER 120 VAC INPUT RECEPTACLE CONNECT TO EXTERNAL 120 VAC POWER SOURCE PANEL JACKET WATER HEATER 120 VAC INPUT RECEPTACLE REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD Figure 56 DCA 45SIU2 Battery Charger amp Jacket Water Heater Power Connections PAGE 42 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ TRAILER MAINTENANCE 1 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 DCA 220SSVU 50 HZ Whisperwatt Generator 1 Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty when trans porting equipment Braking System System employed in stoppi
82. riant Indicated by XXXXX ONLY NOT USED ON XXXX Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 52 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ SUGGESTED SPARE PARTS DCA 220SSVU 50 HZ WHISPER WATTGENRATOR W VOLVO PENTA TAD741GE DIESEL ENGINE 1 TO 3 UNITS Qty P N Description _ _ V3827051 HOSE RADIATOR UPPER 256 V3827052 HOSE RADIATOR LOWER d V866095 RADIATOR CAP 0605505070 FUEL CAP aom V966846 V BELT SET MAIN S N 2071145377 AND BELOW jus V966847 V BELT SET MAIN S N 2071145378 AND ABOVE ALTERNATOR 12 VDC Ti sansi V9146844 V BELT ALTERNATOR V863169 MONITOR OIL PRESSURE V866835 SENSOR OIL PRESSURE V848829 TEMP SENSOR UNIT V862154 SWITCH TEMPERATURE SENSOR 22225 V8488229 SENSOR TEMPERATURE D us V3825133 FILTER FUEL V8159975 FILTE
83. run 1 or 2 minutes to N position warm up At temperatures below freezing this time period must be extended to 2 to 4 minutes 8 When the engine starts immediately check for abnormal noise vibration fluid leakage or any indication of a problem Check the control panel gauges If all is normal let the engine remain at the Low position for a short time depending on the ambient conditions warm u 9 After sufficient warm up time has elapsed set the Engine speed switch to the High position and the unit is ready for operation 10 Check the speed as shown i in table below 60 0Hz 180 11 Adjust the Voltage Regulator to the voltage SAFETY INSTRUCTIONS Improper operation of this machine can cause severe injury or death Read the instruction manual carefully before operating or servicing This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation High voltage circuits are located inside the output terminal cover and control panel Close the cover and control panel before operating Moving parts and hot surfaces are contained within the enclosure Close all doors and lock them before M35200010 P N M3552000103 operating 92010030 9520100304 OIL U W DRAIN PLUGS C W WO W U P N M950000004 OFF OFF P N M9520000104 P N M9520000204 OVER CURRENT RELAY If itis Impossible to rese
84. t the CIRCUIT BREAKER open the control panel and push the RESET BUTTON as below P N M9520200104 P N M9510200002 PIN M9500300104 M9500300004 DIESEL FUEL WATER OIL CHECK AND FILL DAILY M90050000 M90300010 PIN M9500500004 P N M9503000103 Figure 2 Generator Decals PAGE 14 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERATOR DECALS ELECTRIC SHOCK HAZARD ELECTRIC SHOCK HAZARD e Before connecting this generator to any building s electrical system a licensed electrician must install e Dorottouch output e Always complete the grounding an isolation transfer switch terminals when this path from the around terminal ine i this genset to an external machos source See instruction e Serious injury or death may result without this e Turn power off before transfer switch manual for details servicing A WARNING WARNING A WARNING M9520 100503 P N M9520100503 A WARNING HOT COOLANT can cause A WARNING severe burns I ENGINE EXHAUST can cause Do not remove cap if severe injury or death radiator is hot 1 Use only in open well ventilated areas or vent exhaust outside P N M9503100004 P N M9503200004 DANGER CAUTION Stop engine before switching HIGH VOLTAGE A CAUTION M9520100401 MOVING PARTS can cause m severe injury ss O Do not operate with doors open O Stop engine be
85. t will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols A WARNING LETHAL EXHAUST GASES Gasoline engine exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause DEATH if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air WARNING EXPLOSIVE FUEL its vapors can cause an explosion if ignited DO NOT start the engine near spilled fuel or combustible fluids DO NOT fill the fuel tank while the engine 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 approved containers in well ventilated areas and away from sparks and flames Gasoline is extremely flammable and is running or hot NEVER use fuel as a cleaning agent Ah WARNING BURN HAZARDS Engine components can generate extreme A ee ie heat To prevent burns DO NOT touch these areas while the engine is running or immediately after operations NEVER operate the engine with heat shields or heat guards removed A DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH PAGE 8 DCA 220SSVU 50 Hz OPER
86. ted using variable resistive values from the temperature sending unit This is considered a major fault D Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of times and has failed to start The number of cycles and duration are programmable It is pre set at 3 cycles with a 10 second duration This is considered a major fault E Overspeed Shutdown Indicates the engine is running at an unsafe speed This is considered a major fault F Engine Running Indicates that engine is running at a safe operating speed DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 23 DCA 220SSVU 50 HZ OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization The Output Terminal Panel Figure 8 shown below is located The Output Terminal Panel Figure 8 is provided with the on the right hand side left from control panel of the generator following Lift up on the cover to gain access to receptacles and terminal m Thre 3 100 200V output receptacles amp 50 amp e lugs me Three 3 Circuit Breakers O 50 amps Two 2 100V receptacles O 20 am Terminal legs O and Ground 2 P P are considered bonded grounds Two 2 GFCI Circuit Breakers O 20 amps m Five 5 Output Terminal Lugs U V W O Ground gon ae NEUTRAL GROUND OUTPUT TERMINALS TERMINAL TERMINAL HARD WIRE HOOKUP PAN
87. ting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 When connecting a resistance load such as an Incandescent lamp or electric heater a capacity of up to the generating set s rated output kW can be used m When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output kW multiplied by 0 6 can be used m When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output kW multiplied by 0 8 can be used A DANGER ELECTRICAL SYSTEM HAZARDS 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 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 27 DCA 220SSVU 50 HZ GENERATOR OUTPUTS Generator Output Voltages Generator Amperage A wide range of voltages are available to supply voltage for Tables 8 describes the generator s current output capability many different applications Voltages are selected by apply for 3Q phase applications ing jumpers 6 to the voltage chang
88. transfer to a load A DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH To avoid these hazards NEVER use damaged or worn cables when connecting equipment to the generator Make sure power connecting cables are securely connected to the generator s output terminals insufficient tightening of the terminal connections may cause damage to the generator and electrical shock NEVER grab or touch a live power 3 cord with wet hands NEVER touch output terminals eowerow during operation This is extremely dangerous ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals 1 required Backfeed to a utility system can cause electrocution and or property damage DO NOT connect to any building s electrical system except through an approved device or after building main switch is opened ALWAYS have a licensed electrician perform the installation DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 11 DCA 220SSVU 50 HZ RULES FOR SAFE OPERATION Maintenance Safety M The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits Turn all circuit breakers OFF before performing maintenance on the generator NE
89. ty of the battery when connecting the battery A CAUTION BATTERY SERVICING SAFETY 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 corrision 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 lines are defective replace them immediately DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 35 DCA 220SSVU 50 HZ GENERATOR START UP PROCEDURE MANUAL Before Starting A CAUTION LETHAL EXHAUST HAZARD The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel A WARNING STARTING THE GENERATOR NEVER manually start the engine with the main GFCI Or auxiliary circuit breakers in the ON closed position 1 Place t
90. y a 6 cylinder water cooled direct injection turbocharged VOLVO Model PENTA TAD520GE Diesel Engine This engine is designed to meet every performance requirement for the generator Reference Table 1 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 en gine When the engine demand increases or decreases the governor system regulates the frequency variation to 25 Extension Cables When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size PAGE 18 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ MAJOR COMPONENTS Table 4 Generator Major Components s peememy _ s emen _ Figure 5 Major Components DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 PAGE 19 NOTE PAGE PAGE 20 DCA 220SSVU 50 Hz OPERATION AND PARTS MANUAL REV 0 04 18 06 DCA 220SSVU 50 HZ GENERAT
91. y persons in the general area of the generator Battery Safety Use the following guidelines when handling the battery M The battery contains acids that can Cause injury to the eyes and skin To avoid eye irritation always wear safety glasses Use well insulated gloves when picking up the battery a A DANGER EXPLOSION HAZARDS The risk of an explosion exists when performing service on the battery To avoid severe injury or DEATH DO NOT drop the battery There is the possibility of risk that the battery may explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come in contact with a flame or spark an explosion could occur ALWAYS keep the battery charged If the battery is not charged a buildup of combustible gas will occur ALWAYS keep battery charging and cables in good working condition Repair or replace all worn cables ALWAYS recharge the battery in an vented air environment to avoid risk of a dangerous concentration of combustible gases In case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water In case the battery liquid dilute sulfuric acid comes in contact with your EYES rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medi

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