Multiquip Dca220Sscu Users Manual
DCA220SSCU Generators_portable_whisperwatt_DCA220SSCU_SSCU4i_rev_0_60Hz_manual_DataId_98799_Version_1
DCA220SSCU to the manual ede78c49-a0e7-4f6e-b08d-e72ed6dce794
2015-02-09
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Operation and parts Manual ® Whisperwatt™ Series MODEL DCA220SSCU MODEL DCA220SSCU4i 60Hz GENERATOR (CUMMINS QSB7-G6 DIESEL ENGINE) PARTS LIST NO. M4870300204 Revision #0 (10/25/12) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES. proposition 65 warning Diesel engine exhaust and some of page 2 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip. To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to: Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safecar.gov. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 3 Table of Contents DCA220SSCU/SSCU4i Proposition 65 Warning............................................ 2 Reporting Safety Defects.......................................... 3 Table Of Contents..................................................... 4 Safety Information............................................... 6-11 Specifications......................................................... 12 Dimensions............................................................. 13 Installation......................................................... 14-15 General Information................................................ 16 Major Components................................................. 17 Engine Control Unit (ECU)..................................... 18 Engine/Generator Control Panel............................ 19 Output Terminal Panel Familiarization............... 20-22 Load Application..................................................... 23 Generator Outputs.................................................. 24 Generator Outputs/Gauge Reading........................ 25 Output Terminal Panel Connections.................. 26-27 Inspection/Setup................................................ 28-31 Generator Start-Up Procedure (Manual)........... 32-33 Generator Start-Up Procedure (Auto Mode)........... 34 Generator Shut-Down Procedures......................... 35 Maintenance...................................................... 36-41 Trailer Maintenance........................................... 42-45 TTrailer Wiring Diagram.......................................... 46 Generator Wiring Diagram...................................... 47 Engine Wiring Diagram........................................... 48 Troubleshooting (Generator)................................... 49 Troubleshooting Diagnostics ................................. 50 Explanation of Code in Remarks Column.............. 52 Suggested Spare Parts.......................................... 53 Component Drawings Generator Assembly.......................................... 54-57 Control Panel Assembly.................................... 58-59 Control Box Assembly....................................... 60-63 Engine And Radiator Assembly......................... 64-65 Output Terminal Assembly................................. 66-67 Battery Assembly.............................................. 68-69 Muffler Assembly............................................... 70-71 Fuel Tank Assembly........................................... 72-73 Enclosure Assembly.......................................... 74-79 Rubber Seals Assembly .................................. 80-81 Nameplate And Decals Assembly..................... 82-85 Terms And Conditions Of Sale — Parts................. 86 NOTICE Specifications are subject to change without notice. page 4 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) notes DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 5 Safety Information Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others. Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages. saFeTY messages The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifically address the level of exposure to the operator and are preceded by one of four words: danger, Warning, cauTion or noTice. saFeTY sYmBols danger Indicates a hazardous situation which, if not avoided, Will result in deaTh or serious inJurY. Warning Indicates a hazardous situation which, if not avoided, could result in deaTh or serious inJurY. cauTion Indicates a hazardous situation which, if not avoided, could result in minor or moderaTe inJurY. NOTICE Addresses practices not related to personal injury. page 6 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Safety Information general saFeTY cauTion never operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations. never operate this equipment when not feeling well due to fatigue, illness or when under medication. never operate this equipment under the influence of drugs or alcohol. never use accessories or attachments that are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result. alWaYs know the location of the nearest fire extinguisher. alWaYs know the location of the nearest first aid kit. alWaYs know the location of the nearest phone or keep a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency. generaTor saFeTY danger alWaYs check the equipment for loosened threads or bolts before starting. do noT use the equipment for any purpose other than its intended purposes or applications. NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older. Whenever necessary, replace nameplate, operation and safety decals when they become difficult read. Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties. never operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death. Warning never disconnect any emergency or safety devices. These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties. cauTion never lubricate components or attempt service on a running machine. NOTICE alWaYs ensure generator is on level ground before use. alWaYs keep the machine in proper running condition. Fix damage to machine and replace any broken parts immediately. alWaYs store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 7 Safety Information engine saFeTY danger The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. The engine of this equipment requires an adequate free flow of cooling air. never operate this equipment in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine. Warning do noT place hands or fingers inside engine compartment when engine is running. never operate the engine with heat shields or guards removed. Keep fingers, hands hair and clothing away from all moving parts to prevent injury. do noT remove the radiator cap while the engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator. do noT remove the coolant drain plug while the engine is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator. do noT remove the engine oil drain plug while the engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator. cauTion never touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing equipment. NOTICE never run engine without an air filter or with a dirty air filter. Severe engine damage may occur. Service air filter frequently to prevent engine malfunction. never tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable. Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without sufficient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance. In order for a diesel engine to operate at peak efficiency, it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel. Wet stacking does not usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel. State Health Safety Codes and Public Resources Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. page 8 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Safety Information Fuel saFeTY danger do noT start the engine near spilled fuel or combustible fluids. Diesel fuel is extremely flammable and its vapors can cause an explosion if ignited. Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer “gross vehicle weight rating.” alWaYs inspect the hitch and coupling for wear. never tow a trailer with defective hitches, couplings, chains, etc. alWaYs refuel in a well-ventilated area, away from sparks and open flames. Check the tire air pressure on both towing vehicle and trailer. Trailer tires should be inflated to 50 psi cold. Also check the tire tread wear on both vehicles. alWaYs use extreme caution when working with flammable liquids. alWaYs make sure the trailer is equipped with a safety chain. do noT fill the fuel tank while the engine is running or hot. alWaYs properly attach trailer’s safety chains to towing vehicle. do noT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. alWaYs make sure the vehicle and trailer directional, backup, brake and trailer lights are connected and working properly. Store fuel in appropriate containers, in well-ventilated areas and away from sparks and flames. DOT Requirements include the following: never use fuel as a cleaning agent. do noT smoke around or near the equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine. ToWing saFeTY cauTion Check with your local county or state safety towing regulations, in addition to meeting Department of Transportation (DOT) Safety Towing Regulations, before towing your generator. Refer to MQ Power trailer manual for additional safety information. In order to reduce the possibility of an accident while transporting the generator on public roads, alWaYs make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition. alWaYs shutdown engine before transporting • Connect and test electric brake operation. • Secure portable power cables in cable tray with tie wraps. The maximum speed for highway towing is 55 mph unless posted otherwise. Recommended off-road towing is not to exceed 15 mph or less depending on type of terrain. Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing. Avoid sharp turns to prevent rolling. Trailer should be adjusted to a level position at all times when towing. Raise and lock trailer wheel stand in up position when towing. Place chock blocks underneath wheel to prevent rolling while parked. Place support blocks underneath the trailer’s bumper to prevent tipping while parked. Use the trailer’s swivel jack to adjust the trailer height to a level position while parked. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 9 Safety Information elecTrical saFeTY danger do noT touch output terminals during operation. Contact with output terminals during operation can cause electrocution, electrical shock or burn. The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers oFF before performing maintenance on the generator or making contact with output terminals. never insert any objects into the output receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death. Backfeed to a utility system can cause electrocution and/or property damage. never connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious injury or even death. Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator. NOTICE alWaYs make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual. grounding safety danger alWaYs make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. severe injury or death by electrocution can result from operating an ungrounded generator. never use gas piping as an electrical ground. power cord/cable safety danger never let power cords or cables lay in water. never stand in water while AC power from the generator is being transferred to a load. never use damaged or worn cables or cords when connecting equipment to generator. Inspect for cuts in the insulation. never grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death. page 10 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Safety Information BaTTerY saFeTY danger do noT drop the battery. There is a possibility that the battery will explode. do noT expose the battery to open flames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a flame or spark, an explosion could occur. Warning environmenTal saFeTY NOTICE Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters. do noT use food or plastic containers to dispose of hazardous waste. do noT pour waste, oil or fuel directly onto the ground, down a drain or into any water source. alWaYs wear safety glasses when handling the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin. Use well-insulated gloves when picking up the battery. alWaYs keep the battery charged. If the battery is not charged, combustible gas will build up. alWaYs recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses. If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing immediately with plenty of water. If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention. cauTion alWaYs disconnect the negaTive battery terminal before performing service on the generator. alWaYs keep battery cables in good working condition. Repair or replace all worn cables. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 11 Specifications Model Type Table 1. Generator Specifications DCA220SSCU/ DCA220SSCU4i Revolving field, self ventilated, open protected type synchronous generator Star with Neutral 3 194 kW (242 kVA) 176 kW (220 kVA) Armature Connection Phase Standby Output Prime Output 3Ø Voltage (L-L/L-N) 208Y/120, 220Y/127, 240Y/139 Voltage Change-Over Bd. at 3Ø 240/139 3Ø Voltage (L-L/L-N) 416Y/240, 440Y/254, 480Y/277 Voltage Change-Over Bd. at 3Ø 480/277 1Ø Voltage (L-L/L-N) 240/120 Voltage Change-Over Bd. at 1Ø 240/120 Power Factor 0.8 Frequency 60 Hz Speed 1800 rpm Aux. AC Power Single Phase, 60 Hz Aux. Voltage/Output 4.8 Kw (2.4 kW x 2) Dry Weight 6,636 lbs. (3,010 kg) Wet Weight 7,496 lbs. (3,400 kg) Table 2. Engine Specifications Model Cummins QSB7-G6 EPA Interim Tier 4 Certified 4 cycle, water-cooled, direct injection, turbo-charged Type air cooled and EGR No. of Cylinders 6 cylinders Bore x Stroke 4.21 in. x 4.88 in. (107 mm x 124 mm) Displacement 409 cu. in. (6.7 liter) Rated Output 282 HP at 1800 rpm Starting Electric Coolant Capacity 11.4 gal. (43.0 liters)1 Lube Oil Capacity 4.6 gal. (17.5 liters)2 Lubricating Type Oil API service class CJ-4 SAE 15W-40 Fuel Type #2 Diesel Fuel (Ultra low sulfur diesel fuel only) Fuel Tank Capacity 100 gal. (380 liters) 12.4 gal. (46.8 L)/hr at full load 9.5 gal. (36.0 L)/hr at 3/4 load Fuel Consumption 6.9 gal. (26.0 L)/hr at 1/2 load 4.4 gal. (16.8 L)/hr at 1/4 load Battery 27 (CCA 0°F 800A) X 2 1 Includes engine and radiator hoses 2 Includes filters page 12 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Dimensions C B MAXIMUM LIFTING POINT 14,050 lbs. (6,373 kg) TOP VIEW A D E 220 SIDE VIEW F FRONT VIEW Figure 1. Dimensions Table 3. Dimensions G Reference Letter Dimension in. (mm) Reference Letter Dimension in. (mm) A 31.10 in. (790 mm) E 41.33 in. (1,050 mm.) B 31.10 in. (790 mm) F 137.79 in. (3,500 mm) C 41.33 in. (1,050 mm) G 68.89 in. (1,750 mm) D 41.33 in. (1,050 mm) H 51.18 in. (1,300 mm) H DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 13 Installation Figure 2. Typical Generator Grounding Application page 14 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Installation Outdoor Installation Generator Grounding Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes. To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground (Figure 2). The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding. Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts. CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area. Indoor Installation Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical. NEC articles 250-64(b) and 250-66 set the following grounding requirements: 1. Use one of the following wire types to connect the generator to earth ground. a. Copper - 8 AWG (5.3 mm2) b. Aluminum - 6 AWG (8.4 mm2) 2. When grounding the generator (Figure 2) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground. 3. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground. 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. When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician. Mounting This generator has a permanent bonding conductor between the generator stator windings and the frame. NOTICE NOTICE The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 15 General Information Generator Open Delta Excitation System This generator (Figure 3) is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery. Each generator is equipped with the state of the art “OpenDelta” 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. Operating Panel The “Operating Panel” is provided with the following: ECU Controller Gauge Unit Assembly • Oil Pressure Gauge • Water Temperature Gauge • Charging Voltmeter • Fuel Gauge • Tachometer Panel Light/Panel Light Switch Hour Check Button Auto Start/Stop Switch Engine Speed Switch Emergency Stop Button Water Temperature Gauge Control Panel The “Control Panel” is provided with the following: Frequency Meter (Hz) AC Ammeter (Amps) AC Voltmeter (Volts) Ammeter Change-Over Switch Voltmeter Change-Over Switch Voltage Regulator 3-Pole, 600 amp Main Circuit Breaker “Control Box” (located behind Control Panel) • Automatic Voltage Regulator • Current Transformer • Over-Current Relay • Starter Relay Output Terminal Panel The “Output Terminal Panel” is provided with the following: Three 120/240V output receptacles (CS-6369), 50A Three auxiliary circuit breakers, 50A Two 120V output receptacles (GFCI), 20A Two GFCI circuit breakers, 20A Eight output terminal lugs (3Ø power) Ground lug Battery Charger (Optional) Jacket Water Heater (Optional) Engine This generator is powered by a 6 cylinder, 4-cycle water cooled, direct injection, turbocharged, air cooled Cummins qsb7-g6 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine specifications. In keeping with MQ Power’s policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice. Electric Governor System The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%. Extension Cables When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size. page 16 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Major Components 1 2 220 3 6 4 5 220 U V W O GND 7 10 11 25 0 50 75 PSI 140 100 180 260 18 12 220 °F 100 OIL PRESS 24 VOLTS 6 WATER TEMP 30 DECREASE INCREASE BATTERY ½ 120 150 180 60 E F FUEL 0 RPMX10 V 210 SPEED U W OFF ECU V-W Series 800 Controller Engine Started Shutdown W-U U-V OFF Pre-Alarm Screen Alarm Acknowledge Change Option Program/ Exit 9 Denyo 8 Table 4. Generator Major Components ITEM NO. DESCRIPTION 1 Muffler Assembly 2 Enclosure Assembly 3 Generator Assembly 4 Battery Assembly 5 Engine Assembly 6 Fuel Tank Assembly 7 Output Terminal Assembly 8 Circuit Breaker Assembly 9 Auto Start/Stop Controller Assembly 10 Gauge Unit Assembly 11 Operating Panel Assembly Figure 3. Major Components DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 17 engine control unit (ecu) 1 ECU Series 800 Controller Engine Started Shutdown A Pre-Alarm B C D 25 0 50 75 PSI 140 100 180 260 18 12 220 °F 100 OIL PRESS 24 VOLTS 6 WATER TEMP 30 INCREASE ½ 120 150 180 60 E °F FUEL F DECREASE BATTERY 0 RPMX10 V 210 SPEED U W OFF ECU V-W Series 800 Controller Engine Started Shutdown W-U U-V OFF Pre-Alarm Alarm Screen Acknowledge Change E Option F G Alarm Screen Acknowledge Change Program Exit Option Program Exit H Figure 4. Engine Control Unit (ECU) The definitions below describe the controls and functions of the Engine Control Unit (Figure 4). 1. ECU Controller — This auto start/stop controller displays the parameters and the diagnostic troubleshooting messages of the engine, and controls DPF regeneration. A. ECU Display Screen — Engine fault diagnostic messages are shown on this LCD display. screen B. Engine Started Lamp — This lamp when lit indicates engine is operating normally. C. Engine Shutdown Lamp — When an engine failure has occured this lamp will blink. Indicating the engine has been shutdown. The diagnostic fault message will be displayed on the LCD screen. D. Pre Alarm Lamp — When an engine failure has occured this lamp will blink. Indicating a pre-fault engine condition and the possibility of engine shutdown.The diagnostic fault message will be displayed on the LCD screen E. Alarm Acknowledge Button — When the engine experiences a fault, the "Pre Alarm Lamp" or the "Shutdown Lamp" will start blinking. Pushing this button will confirm the fault message and the blinking lamp will change to a solid lamp display. The fault message will be displayed on the screen. When multiple engine faults occur, the lamp will continue blnking until all fault messages are confirmed. The blinking lamp will change to a solid lamp display all current confirmed fault messages will scrool across the screen. F. Screen Change Button — When this button is pushed during operation, the screen will cycle through each parameter screen. G. Option Button — This button is not active. Do not use. H. Program/Exit Button — Pushing this button allows the DPF Force Regen and diagnostic code to be confirmed. page 18 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) ENGINE/Generator Control Panel 1 3 2 4 7 25 0 50 75 PSI A 140 100 100 180 °F B 18 12 220 25 0 24 VOLTS 6 260 C 50 75 PSI 140 100 OIL PRESS 180 260 120 150 INCREASE DECREASE 8 180 60 °F F FUEL WATER TEMP 30 BATTERY ½ E OIL PRESS 24 VOLTS 6 WATER TEMP 30 18 12 220 °F 100 0 RPMX10 14 V 210 SPEED U BATTERY W OFF D 120 150 V-W 180 ECU Series 800 Controller 60 E °F FUEL F 9 5 E ½ 0 U-V Engine Started RPMX10 OFF Shutdown 210 W-U Pre-Alarm SPEED 6 Alarm Screen Acknowledge Change 13 Option Program Exit 11 10 12 Figure 5. Gauge Unit Assembly The definitions below describe the controls and functions of the Engine/Generator Control Panel (Figure 5). 1. Gauge Unit Assembly — This assembly houses the various engine monitoring gauges. These gauges indicate: oil pressure, water temperature, charging voltmeter, fuel and engine speed RPM (tachometer). A. Oil Pressure Gauge — During normal operation this gauge be should read between 35 to 65 psi. (241~448 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range. B. Water Temperature Gauge — During normal operation this gauge be should read between 180° and 225°F (82°~107°C). C. Charging Voltmeter Gauge — During normal operation this gauge indicate minimum 26 VDC D. Fuel Gauge — Indicates amount of diesel fuel available. E. Tachometer — Indicates engine speed in RPM’s for 60 Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. . 2. Panel Light — For operation at night, panel light illuminates control panel for ease of reading meters and gauges. Make sure oanel light switch is in the OFF position when light is not in use. 3. Panel Light Switch — When activated will turn on control panel light. 4. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz 5. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch. 6. AC Voltmeter — Indicates the output voltage present at the U,V, and W Output Terminal Lugs. 7. Voltage Regulator Control — Allows ±15% manual adjustment of the generator’s output voltage. 8. Ammeter Change-Over Switch — This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only. 9. Voltmeter Change-Over Switch — This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off. 10. Emergency Stop Button — Push this button inward to stop the engine in the event of an emergency. DO NOT use this button as a means of stopping the engine. 11. Engine Speed Switch — This switch controls the speed of the engine (low/high). 12. Auto/Start Switch — This switch selects either manual or automatic operation . Center position is OFF (reset). 13. Hour Check Button — With the engine stopped, press and hold ths button. The total running hours, fuel level, and battery voltage will be displayed. 14. Main Circuit Breaker — This three-pole, 600 amp main breaker is provided to protect the U,V, and W Output Terminal Lugs from overload. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 19 OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization The Output Terminal Panel (Figure 7) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs. The “Output Terminal Panel ” (Figure 7) is provided with the following: Three (3) 240/139V output receptacles @ 50 amp Three (3) Circuit Breakers @ 50 amps NOTICE Terminal legs “O” and “Ground” are considered bonded grounds Two (2) 120V GFCI receptacles @ 20 amp Two (2) GFCI Circuit Breakers @ 20 amps Eight (8) Output Terminal Lugs ( U, V, W, O, Ground) 1Ø AND 3Ø, 480 -120 VAC OUTPUT TERMINALS NEUTRAL TERMINAL GROUND TERMINAL HARD WIRE HOOKUP PANEL U V W O BLACK RED BLUE WHITE GREEN CIRCUIT BREAKERS FOR CS-6369 TWIST LOCK RECEPTACLES CIRCUIT BREAKERS FOR GFCI RECEPTACLES 120 VAC, 20 AMP GFCI RECEPTACLES Y W X CS-6369 TWIST-LOCK AUX. POWER RECEPTACLES 240/139V, 50 AMPS Figure 6. Output Terminal Panel page 20 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board configuration. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs. Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month. Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the output terminal lugs. Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage. Figure 9. Voltage Regulator Control Knob Figure 7. G.F.C.I. Receptacle Twist Lock Dual Voltage 120/240 VAC Receptacles There are three 240/139V, 50 amp auxiliary twist-lock (CS6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage change-over board is configured for single-phase 240/120 application Figure 8. 240/139V Twist-Lock Auxiliary Receptacles DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 10). Make sure to read the operation manual before attempting to connect a load to the generator. An over current relay (Figure 11) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box. 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. Figure 11. Over Current Relay NOTICE Figure 10. Connecting Loads Remember the overcurrent relay monitors the current flowing from the U,V, and W Output Terminal Lugs to the load. In the event of a short circuit or over current condition, it will automatically trip the 600 amp main breaker. To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the main circuit breaker in the closed position (ON). page 22 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Load Application Single Phase Load Three 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. When calculating the power requirements for 3-phase power use the following equation: Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment. NOTICE If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732 NOTICE If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage. WATTS = VOLTAGE x AMPERAGE The power factor of this generator is 0.8. See Table 5 below when connecting loads. Table 5. Power Factor By Load Type of Load Power Factor Single-phase induction motors 0.4-0.75 Electric heaters, incandescent lamps Fluorescent lamps, mercury lamps Electronic devices, communication equipment Common power tools 1.0 0.4-0.9 Load in Watts At 100 Volts 2.5 5 0.8 Maximum Allowable Cable Length At 200 Volts #10 Wire #12 Wire #14 Wire #16 Wire 300 600 1000 ft. 600 ft. 375 ft. 250 ft. 600 1200 500 ft. 300 ft. 200 ft. 125 ft. 7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft. 10 1200 2400 250 ft. 150 ft. 100 ft. 15 1800 3600 150 ft. 100 ft. 65 ft. 2400 4800 125 ft. 75 ft. 50 ft. 20 Motors and motor-driven equipment draw much greater current for starting than during operation. An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6. When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used. When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used. When connecting an electric drill or other power tools, pay close attention to the required starting current capacity. 1.0 Table 6. Cable Selection (60 Hz, Single Phase Operation) Current in Amperes NOTICE When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used. DANGER Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch. CAUTION: Equipment damage can result from low voltage DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 23 GENERATOR OUTPUTS Generator Output Voltages Maximum Amps A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the voltage change-over board (Figure 12). To obtain some of the voltages as listed in Table 7 (see below) will require a fine adjustment using the voltage regulator (VR) control knob located on the control panel. Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed. Voltage Change-Over Board The voltage change-over board (Figure 12) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection. Table 8. Generator Maximum Amps Model DCA220SSCU/ DCA220SSCU4i Rated Voltage Maximum Amps Single Phase 120 Volt 488.9 amps (4 wire) Single Phase 240 Volt 244.4 amps (4 wire) Three Phase 240 Volt 529 amps Three Phase 480 Volt 264 amps Figure 12. Voltage Change-Over Board CAUTION NEVER attempt to place jumper plates on the voltage change-over board while the generator is in operation. There exist the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even death! Table 7. Voltages Available UVWO Output Terminal Lugs Voltage Change-Over Board 3-Phase 240/139V Position Voltage Change-Over Board 3-Phase 480/270V Position 3Ø Line-Line 208V 220V 240V 416V 440V 480V 1Ø Line-Neutral 120V 127V 139V 240V 254V 277V Voltage Change-Over Board Single-Phase 240/120V Position 1Ø Line-Neutral/ Line-Line 120V Line-Neutral N/A N/A 240V Line-Line N/A N/A page 24 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) GENERATOR OUTPUTS/gauge reading how to Read the ac ammeter and ac voltage gauges The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches. Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs. AC Ammeter Gauge Reading Place the AC Ammeter Change-Over Switch (Figure 16) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 17). This process can be repeated for terminals V and W. Before taking a reading from either gauge, configure the Voltage Change-Over Board (Figure 13) which produces the desired output voltage. Figure 16. AC Ammeter Change-Over Switch Figure 17. AC Ammeter (Amp reading on U Lug) NOTICE The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use. Figure 13. Voltage Change-Over Board 240/3Ø Position AC Voltmeter Gauge Reading Place the AC Voltmeter Change-Over Switch (Figure 14) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 15). Figure 14. AC Voltmeter Change-Over Switch Figure 15. AC Voltmeter Gauge (Volt reading on W-U Lug) DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 25 OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the Voltage Change-Over Board and the adjustment of the Voltage Regulator Control Knob. Remember the voltage change-over board determines the range of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage. 3Ø-240V UVWO Terminal Output Voltages 3. Turn the voltage regulator knob (Figure 20) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required Figure 20. Voltage Regulator Knob 1Ø-240V UVWO Terminal Output Voltages 1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18. 2. Connect the load wires to the UVWO terminals as shown in Figure 21. 1. Jumper the voltage change-over board for 240V operation as shown in Figure 18 Figure 21. UVWO Terminal Lugs 1Ø-240V Connections 1Ø-120V UVWO Terminal Output Voltages Figure 18. Voltage Change-Over Board 240V Configuration 2. Connect the load wires to the UVWO terminals as shown in Figure 19. Figure 19. UVWO Terminal Lugs 1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 18. 2. Adjust voltage regulator knob (Figure 20) for an output of 208V to obtain 120V at the UVWO terminals. 3. Connect the load wires to the UVWO terminals as shown in Figure 22. Figure 22. UVWO Terminal Lugs 1Ø-120V Connections page 26 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480V UVWO Terminal Output Voltages 1Ø-480V UVWO Terminal Output Voltages 1. Jumper the voltage change-over board for 480V operation as shown in Figure 23. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used. 1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 23. Figure 23. Voltage Change-Over Board 480V Configuration 2. Connect the load wires to the UVWO terminals as shown in Figure 24. 2. Connect the load wires to the UVWO terminals as shown in Figure 25. Figure 25. UVWO Terminal Lugs 1Ø-480V Connections 1Ø-277V UVWO Terminal Output Voltages 1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 23. 2. Connect the load wires to the UVWO terminals as shown in Figure 26. Figure 24. UVWO Terminal Lugs 3Ø-480V Connections NOTICE ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a fire. Figure 26. UVWO Terminal Lugs 1Ø-277V Connections DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 27 inspection/SETUP Circuit Breakers To protect the generator from an overload, a 3-pole, 600 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine. Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level and verify that the oil level is maintained between the two notches (Figure 27) on the dipstick. See Table 9 for proper selection of engine oil. Fuel Check DANGER Fuel spillage on a hot engine can cause a fire or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator. Refilling the Fuel System CAUTION ONLY properly trained personnel who have read and understand this section should refill the fuel tank system. This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 28). ALWAYS fill the fuel tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their capacities. Figure 27. Engine Oil Dipstick When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Cummins Engine Owner’s Manual. Oil should be warm before draining. Delo® engine oil is the recommended engine oil for this generator. When replacing engine oil please refill using Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil. Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately. Generator Internal Fuel Tank Table 9. Recommended Motor Oil Trailer Fuel Tank Figure 28. Internal Fuel Tank System page 28 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) inspection/SETUP Refueling Procedure: 4. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 30). WARNING Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes. 3. Level Tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 29). CAUTION ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank. 300 d oun Gr vel Unle Level Ground = DO NOT fill on unlevel ground ! Figure 30. Fueling the Generator 5. NEVER overfill fuel tank — It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 31). ! und Gro vel Unle Level Ground Figure 29. Only Fill on Level Ground NOTICE ONLY use #2 diesel fuel when refueling. Figure 31. Full Fuel Tank CAUTION DO NOT OVERFILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 32). Figure 32. Fuel Expansion DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 29 inspection/SETUP Coolant (Antifreeze/Summer Coolant/ Water) Cummins recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the Cummins Engine Owner’s Manual for further details. Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected. Air Cleaner WARNING If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns. Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 10 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings. Periodic cleaning/replacement is necessary. Inspect air cleaner in accordance with the Cummins Engine Owner’s Manual. Fan Belt Tension A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Cummins Engine Owner’s Manual. The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 33) when depressed with the thumb as shown below. Table 10. Coolant Capacity Engine and Radiator 11.4 gal (43 liters) Reserve Tank N/A Operation in Freezing Weather When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added. Table 11. Anti-Freeze Operating Temperatures Freezing Point Vol % Anti-Freeze °C °F 50 -37 -34 Figure 33. Fan Belt Tension CAUTION NEVER place hands near the belts or fan while the generator set is running. NOTICE When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. page 30 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) inspection/SETUP Battery When connecting battery do the following: 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. 1. NEVER connect the battery cables to the battery terminals when the Auto-Off/Reset-Manual Switch is in either the AUTO or MANUAL position. ALWAYS make sure that this switch is in the OFF/RESET position when connecting the battery. DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27. 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. The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced. Before charging the battery with an external electric source, be sure to disconnect the battery cables. Battery Cable Installation ALWAYS be sure the battery cables (Figure 34) are properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery. CAUTION ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST. NOTICE If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery. CAUTION Inadequate battery connections may cause poor starting of the generator, and create other malfunctions. Alternator The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure. DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator. Wiring Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately. Piping and Hose Connection Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks. Figure 34. Battery Connections If any hose (fuel or oil) lines are defective replace them immediately. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 31 GENERATOR START-UP PROCEDURE (MANUAL) Before Starting Starting (Manual) CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. 1. Place the engine speed switch (Figure 37) in the LOW (down) position. Figure 37. Engine Speed Switch (Low) WARNING NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position. 1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 35) in the OFF position prior to starting the engine. 2. Place the Auto-Off/Reset Manual Switch in the MANUAL position to start the engine (Figure 38). Figure 38. Auto-Off/Reset Manua;Switch (Manual Position) NOTICE If engine fails to start in a specified number attempts, the shutdown lamp will illuminate and the Auto-Off/ Reset Switch must be place inthe Off/Reset position before the engine can be restarted. Figure 35. Main, Aux. and GFCI Circuit Breakers (OFF) 2. Make sure the voltage change-over board has been configured for the desired output voltage. 3. Connect the load to the receptacles or the output terminal lugs as shown in Figure 10. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel. 4. Tighten terminal nuts securely to prevent load wires from slipping out. NOTICE Engine will pre-heat automatically in cold weather conditions." Glow Plug Hold " message will be displayed and the engine will start automatically after pre-heating.. 3. Once the engine starts, let the engine run for 1-2 minutes (let engine idle longer in cold weather conditions). Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem. If the engine is running smoothly, place the engine speed switch (Figure 39) in the HIGH (up) position. 5. Close all engine enclosure doors (Figure 36). Figure 39. Engine Speed Switch (High) 4. The generator’s frequency meter (Figure 40) should be displaying the 60 cycle output frequency in HERTZ. CORRECT INCORRECT Figure 36. Engine Enclosure Doors Figure 40. Frequency Meter page 32 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) GENERATOR START-UP PROCEDURE (MANUAL) 5. The generator’s AC-voltmeter (Figure 41) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, 140 180 220 °F 100 260 WATER TEMP Figure 41. Voltmeter 6. Use the voltage adjustment control knob (Figure 42) to increase or decrease the desired voltage. Figure 45. Coolant Temperature Gauge 10. The tachometer gauge (Figure 46) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s. 120 150 180 60 Figure 42. Voltage Adjust Control Knob 7. The ammeter (Figure 43) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator. 0 RPMX10 210 SPEED Figure 46. Engine Tachometer Gauge 11. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 47). Figure 43. Ammeter (No Load) 8. The engine oil pressure gauge (Figure 44) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (193~586 kPa). 25 0 50 75 PSI 100 Figure 47. Main, Aux. and GFCI Circuit Breakers (ON) 12. Observe the generator’s ammeter (Figure 48) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use. OIL PRESS Figure 44. Oil Pressure Gauge 9. The coolant temperature gauge (Figure 45) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 180°~225°F (75°~95°C) (Green Zone). Figure 48. Ammeter (Load) 13. The generator will run until manually stopped or an abnormal condition occurs. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 33 GENERATOR START-UP PROCEDURE (AUTO MODE) Starting (Auto Mode) DANGER Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch. CAUTION When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator’s internal battery charger. This will ensure that the engine will not fail due to a dead battery. When starting generator in AUTO mode use the “Manual Start-up” procedure except where noted (see below). 1. Perform steps 1 through 5 in the Before Starting section as outlined in the Manual Starting Procedure. 2. Place the Engine Speed Switch (Figure 49) in the HIGH position Figure 49. Engine Speed Switch (High) 3. Place the Auto Off/Reset Manual Switch (Figure 50) in the AUTO position. NOTICE When the generator is set in the AUTO mode, the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch. Figure 50. Auto Off/Reset Manual Switch (AUTO) 4. Continue operating the generator as outlined in the Manual Start-up procedure (start at step 5). WARNING When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode. CAUTION The engine speed switch must be set to the “High” position when running in the auto-start mode. Failing to set the switch in the proper position can result in damage to your generator when it turns on. NOTICE When the Auto Off/Reset Manual switch is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically. page 34 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) GENERATOR SHUT-DOWN PROCEDURES WARNING NEVER stop the engine suddenly except in an emergency. Normal Shutdown Procedure To shutdown the generator, use the following procedure: 1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 51 to the OFF position. 6. Remove all loads from the generator. 7. Inspect entire generator for any damage or loosening of components that may have occurred during operation. Emergency Shutdown Procedure 1. To stop the engine in the event of an emergency, PUSH the emergency stop button (Figure 54) inward. This button is located on the engine operating panel, see Figure 5. Figure 54. Emergency Stop Button NOTICE Figure 51. Main, Aux. and GFCI Circuit Breakers (OFF) 2. Place the Engine Speed Switch (Figure 52) in the “LOW” (down) position. The emergency stop pushbutton switch is a push-lock type switch. The switch contacts will remain locked once the button has been pushed. To release the switch contacts rotate the button clockwise. The engine will not start unless the contacts are released. Figure 52. Engine Speed Switch (Low) 3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied. 4. Place the Auto Off/Reset Manual Switch (Figure 53) in the OFF/RESET position. Figure 53. Auto Off/Reset Manual Switch (Off/Reset) 5. Verify that all status LEDs on the ECU control panel are OFF (not lit). DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 35 Maintenance 10 Hrs DAILY X X X X X X Table 12. Inspection/Maintenance Engine Generator Check Engine Fluid Levels Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Replace Engine Oil and Filter * 1 Clean Air Filter Check Fuel Filter/Water Separator Bowl Clean Unit, Inside and Outside Change Fuel Filter Clean Radiator and Check Coolant Protection Level*2 Replace Air Filter Element * 3 Check all Hoses and Clamps * 4 Clean Inside of Fuel Tank Measure Insulation Resistance Over 3M ohms Check Rotor Rear Support Bearing 250 Hrs 500 Hrs 1000 Hrs X X X X X X X X X X X *1 Replace engine oil and filter at 100 hours, first time only. *2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant. *3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20). *4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot, with no sags or dips that could collect moisture and/or oil. General Inspection Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 12 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual) Air Cleaner Every 250 hours: Remove air cleaner element (Figure 55) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed. Air Cleaner with Dust Indicator This indicator () is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator. Figure 55. Air Cleaner/Indicator NOTICE The air filter should not be changed until the indicator reads “RED”. Dispose of old air filter. It may not be cleaned or reused.. page 36 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Maintenance If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists. Fuel Addition Add diesel fuel (the grade may vary according to season and locations). Removing Water from the Fuel Tank After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required. During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel. Cleaning Inside the Fuel Tank Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 56) wash out any deposits or debris that have accumulated inside the fuel tank. Fuel Tank Inspection In addition to cleaning the fuel tank, the following components should be inspected for wear: Rubber Suspension — look for signs of wear or deformity due to contact with oil. Replace the rubber suspension if necessary. Fuel Hoses — inspect nylon and rubber hoses for signs of wear, deterioration and hardening. Fuel Tank Lining — inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter. Replacing Fuel Filter Replace the fuel filter cartridge with new one every 500 hours or so. Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly. Vent any air Air Removal If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the Cummins Engine Manual for details. Figure 56. Fuel Tank Cleaning DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 37 Maintenance To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system. Check Oil Level Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 27. Radiator Cleaning The radiator (Figure 57) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling fins or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the fins and tube. Replacing Oil Filter Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter. After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine. Flushing Out Radiator and Replacing Coolant Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain. Figure 57. Radiator Cleaning Generator Storage For long term storage of the generator the following is recommended: Drain the fuel tank completely. Treat with a fuel stabilizer if necessary. Check hoses for softening and kinks. Check clamps for signs of leakage. Completely drain the oil from the crankcase and refill if necessary with fresh oil. Tighten both cocks and replace the overflow tank. Clean the entire generator, internal and external. Replace with coolant as recommended by the engine manufacturer. Cover the generating set and store in a clean, dry place. Close radiator cap tightly. Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver. 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. WARNING Allow engine to cool when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam. page 38 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Maintenance Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL) This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel. The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger. If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size. NOTICE To ensure adequate starting capability, always have power applied to the generator's internal battery charger.. 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. Figure 58. Battery Charger and Jacket Water Heater Power Connections DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 39 Maintenance Emission control The emission control system employed with the Cummins QSB&-G6 diesel engine consist of a Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). The oxidation catalyst and particulate filter are housed in one unit. See Figure 61. These devices help in filtering out large amounts of harmful Nitrogen Oxides (NOx) and Particulate Matter (PM) which are emitted by diesel engines. These exhaust emissions pose serious environmental and health risks. It is important to maintain and service this DOC/DPF emission safety device on a periodic basis. Diesel Oxidation Catalyst (DOC) The DOC does not filter particles it oxidizes them. This catalyst (honeycomb like structure) uses a chemical process to break down pollutants in the exhaust stream into less harmful components. In general this catalyst collects/burns accumulated particulates. The DOC contains palladium and platinum which serve as a catalysts to oxidize hydrocarbons and carbon monoxide. Forced (Stationary) Regeneration — A forced regeneration only occurs when the operator has initiated this action at the ECU and the ECM recognizes a preprogrammed set point of soot in the PDF to allow a forced regeneration cycle. This process can take anywhere from 30 minutes to 1-1/2 hours. When forced regeneration is in process all loads must be removed from the generator, all circuit breakers must be placed in the OFF position (OPEN), and the engine speed set to idle. DPF pre-alarm In the event the Engine Control Unit (ECU) determines the soot level back pressure and/or tempertaure has reached a pre-determined trip point the ECU will indicate a maintenance action is required by the operator. This maintenance action will be shown on the LCD display (DPF Warning Symbol) and the AMBER pre-alarm LED on the ECU control panel will be ON (lit). See Figure 59. ECU Series 800 Controller Diesel Particulate Filter (DPF) Engine Started DPF STAT A diesel particulate filter (DPF) is a device designed to remove diesel particulate matter (soot) from the exhaust gas of a diesel engine. This type of filter usually removes about 85-95% of the soot. Soot accumulated in the DPF is removed via the "regeneration process". Regeneration is the process of removing the accumulated soot from the filter. This regeneration process can occur in a few different ways. Passive Regeneration — Occurs during normal operation, typically under heavy load applications. Soot is oxidized faster than it is collected. Active Regeneration — Occurs when engine exhaust temperatures are not high enough to oxidize the soot collected in the DPF. Active regeneration requires assistance from the engine to help increase the heat level in the after-treatment system. Active regeneration occurs at a normal engine speed of 1800 rpm. In addition active regeneration is initiated automatically by the Engine Control Module (ECM) timer based program every 96 hours. This timer base program will reset at the end of any regeneration mode. Shutdown Pre-Alarm Alarm Screen Acknowledge Change Option Program Exit Figure 59. ECU DPF Pre-Alarm The DPF pre-alarm status symbol displayed in Figure 59 indicates the soot level buildup has exceeded a predetermined level and a "Forced Regeneration" action is required. NOTICE If the AMBER pre-alarm warning LED is ever ON, the operator should always take immediate action to correct the problem. If the engine is allow to run under this condition, a higher pressure differential will be created in the DPF and will result in the RED status LED being ON, causing an engine shutdown. page 40 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Maintenance ECU Forced regeneration procedure Follow the steps below to initiate a forced regeneration: Series 800 Controller Engine Started DPF STAT Shutdown Pre-Alarm 1. Verify that the AMBER pre-alarm LED is ON or FLASHING and the DPF symbol is shown on the ECU display. 2. Place all circuit breakers in the OFF position. 3. Place the engine speed switch in the LOW position. Alarm Screen Acknowledge Change Option Program Exit Figure 60. ECU DPF Engine Shutdown NOTICE If the RED engine shutdown LED is ever ON (Figure 60), Cummins recommends that the DPF be removed, cleaned or replaced. In addition the shutdown code must be cleared. To clear the code, the ECM must be reset by a licensed Cummins Engine Service Technician, using Cummins service software. NOTICE Soot and ash will accumulate in the DPF over time and must be cleaned. The ash is a result of the normal oil consumption while the engine is operated. The ash cleaning interval will largely depend on the engine's duty cycle and condition. Normal service intervals for cleaning ash from the DPF is every 6 months (5000 hours). 4. Press the Program/Exit button on the ECU controller and select FORCE REGEN mode. 5. Press and hold the request until the REGEN ACTIVE message is displayed on the screen, then release. 6. Once activated, regeneration will start automatically and the engine idling speed will increase through the forced regeneration cycle. This process will last anywhere from 30 minutes to 1-1/2 hours. NOTICE During the regeneration cycle the High Exhaust System Temperature (HEST) symbol may be displayed. Display of this symbol can be considered normal during the regeneration period. ENGINE EXHAUST (OUT) DIESEL PARTICULATE FILTER (DPF) Figure 61. Typical DOC/DPF Unit DIESEL OXIDATION CATALYST (DOC) ENGINE EXHAUST (IN) DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 41 Trailer Maintenance Trailer Maintenance This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment. The definitions below describe some of the major components of a typical trailer that would be used with the generator. 1. Fuel Cell — Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment. 2. Braking System — System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air. 3. GVWR — Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty). 4. Frame Length — Measurement is from the ball hitch to the rear bumper (reflector). 5. Frame Width — Measurement is from fender to fender 6. Jack Stand — Trailer support device with maximum pound requirement from the tongue of the trailer. 7. Coupler — Type of hitch used on the trailer for towing. 8. Tire Size — Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim. 9. Tire Ply — The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc. 10. Wheel Hub — The wheel hub is connected to the trailer’s axle. 11. Tire Rim — Tires mounted on a tire rim. The tire rim must match the size of the tire. 12. Lug Nuts — Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 16 and Figure 62 for lug nut tightening and sequence. 13. Axle — Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds. 14. Suspension — Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride. 15. Electrical — Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle. 16. Application — Indicates which units can be employed on a particular trailer. page 42 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Trailer Maintenance Brakes Hydraulic Surge Brakes Trailer brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently. Figure 62 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 13 as listed below: Hydraulic surge brakes (Figure 62) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage. Brake Adjustment 1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground. 2. Check the wheel and drum for free rotation. 3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate. 4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes. 5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn. 6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag. 7. Replace the adjusting hole cover and lower the trailer to the ground. 8. Repeat steps 1 through 7 on the remaining brakes. Figure 62. Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying hydraulic pressure to the trailer brakes. Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator. Table 13. Hydraulic Brake Troubleshooting Symptom Possible Cause Solution No Brakes Brake line broken or kinked? Repair or replace. Brake lining glazed? Reburnish or replace. Weak Brakes or Brakes Pull to One Side Locking Brakes Noisy Brakes Dragging Brakes Trailer overloaded? Correct weight. Brake drums scored or grooved? Machine or replace. Tire pressure correct? Inflate all tires equally. Tires unmatched on the same axle? Match tires. Brake components loose, bent or broken? Replace components. Brake drums out-of-round? Replace. System lubricated? Lubricate. Brake components correct? Replace and correct. Brake lining thickness incorrect or not adjusted correctly? Install new shoes and linings. Enough brake fluid or correct fluid? Replace rubber parts fill with dot 4 fluid. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 43 Trailer Maintenance Tires/Wheels/Lug Nuts Suspension 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. The leaf suspension springs and associated components (Figure 63) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components as detailed in Table 15. CAUTION ALWAYS wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury. CAUTION DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury. Figure 63. Major Suspension Components Tire Wear/Inflation Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inflation pressure weekly during use to insure the maximum tire life and tread wear. Table 14 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems. Table 14. Tire Wear Troubleshooting Spring Eye Bolt Wear Pattern Cause Item Torque (Ft.-Lbs.) 3/8" U-Bolt Min-30 Max-35 7/16" U-Bolt Min-45 Max-60 1/2" U-Bolt Min-45 Max-60 Shackle Bolt Snug fit only. Parts must rotate freely. Locking nuts or cotter pins are provided to retain nut-bolt assembly. Solution Shoulder Type Shackle Bolt Center Wear Over inflation. Adjust pressure to particular load per tire manufacturer. Edge Wear Under inflation. Adjust pressure to particular load per tire manufacturer. Side Wear Loss of camber or overloading. Make sure load does not exceed axle rating. Align wheels. Toe Wear Incorrect toe-in. Align wheels. Cupping Out-of-balance. Check bearing adjustment and balance tires. Wheel lockup and tire skidding. Avoid sudden stops when possible and adjust brakes. Flat Spots Table 15. Suspension Torque Requirements Min-30 Max-50 page 44 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) 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 64). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 16. 3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically. Table 16. Tire Torque Requirements Wheel Size First Pass FT-LBS Second Pass FT-LBS Third Pass FT-LBS 12" 20-25 35-40 50-65 13" 20-25 35-40 50-65 14" 20-25 50-60 90-120 15" 20-25 50-60 90-120 16" 20-25 50-60 90-120 Figure 64. Wheel Lug Nuts Tightening Sequence NOTICE NEVER use an pneumatic air gun to tighten wheel lug nuts. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 45 Trailer Wiring Diagram Figure 66. Trailer/Towing Vehicle Wiring Diagram page 46 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Generator Wiring Diagram Figure 67. Generator Wiring Diagram DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 47 Engine Wiring Diagram Figure 68. Engine Wiring Diagram page 48 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Troubleshooting (Generator) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Symptom No Voltage Output Low Voltage Output High Voltage Output Circuit Breaker Tripped Table 17. Generator Troubleshooting Possible Problem Solution AC Voltmeter defective? Check output voltage using a voltmeter. Is wiring connection loose? Check wiring and repair. Is AVR defective? Replace if necessary. Defective Rotating Rectifier? Check and replace. Defective Exciter Field? Check for approximately 19 ohms across J & K on CN1 Is engine speed correct? Turn engine throttle lever to “High”. Is wiring connections loose? Check wiring and repair. Defective AVR? Replace if necessary. Is wiring connections loose? Check wiring and repair. Defective AVR? Replace if necessary. Short Circuit in load? Check load and repair. Over current? Confirm load requirements and reduce. Defective circuit breaker? Check and replace. Over current Relay actuated? Confirm load requirement and replace. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 49 Troubleshooting Diagnostics The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. 1. With the engine stopped (OFF). Push and hold the Hour Check Button (Figure 69) located on the control panel. HOUR CHECK BUTTON 5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode enables the ability to carry out the fault diagnostics as listed below: DM1 Active Faults — Displays active fault messages and codes. DM2 Messages and Codes — Displays messages and codes which previously occurred that are recorded in the Engine Control Module (ECM). Last Shutdown — Displays the messages and codes that caused the most recent shutdown. 6. After perfoming diagnostic tests, place the Auto Off/ Reset Manual Switch in the OFF position Figure 69. Hour Check Button 2. While keeping the Hour Check Button pressed, place the Auto Off/Reset Manual Switch (Figure 70) in the MANUAL position. Figure 70. Auto-Off/Reset Switch (Manual Position) 3. The Hour Check Menu Screen will be displayed on the ECU controller. 4. Releasing the Hour Check Button and pushing the Program/Exit Button on the ECU controller will return the controller to the main screen. page 50 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) notes DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 51 Explanation of Code in Remarks Column The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. NOTICE The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed. sample parTs lisT no. 1 2% 2% 3 4 parT no. parT name qTY. remarKs 12345 BOLT .....................1 .....INCLUDES ITEMS W/% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY 12348 HOSE ..................A/R ...MAKE LOCALLY 12349 BEARING ..............1 .....S/N 2345B AND ABOVE no. column qTY. column numbers used — Item quantity can be indicated by a number, a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold separately. Other entries will be clarified in the “Remarks” Column. remarKs column Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown. assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased. unique symbols — All items with same unique symbol Indicated by: “INCLUDES ITEMS W/(unique symbol)” (@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column. serial number Break — Used to list an effective serial number range where a particular part is used. duplicate item numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine. NOTICE When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order. parT no. column numbers used — Part numbers can be indicated by a number, a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication. A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column. Indicated by: “S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N 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 on a specific model or model number variant. Indicated by: “XXXXX ONLY” “NOT USED ON XXXX” “make/obtain locally” — Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts. “not sold separately” — Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip. page 52 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) Suggested Spare Parts dca220ssCU/DCA220SSCU4i WHISPERWATT GENERATOR with cummings qsb7-g6 DIESEL ENGINE 1 to 3 units Qty. P/N Description 3............Y0602015150........HOSE, RADIATOR, hump 2............Y0602015151........HOSE, RADIATOR 2............Y0602015152........HOSE, RADIATOR 1............Y0602015153 .......hose, radiator 3............Y0602015246........BELT, fan 1............4921517.................SENSOR, oil pressure 1............Y0602211320........SWITCH, COOLANT LEVEL 6............Y0602042578........FUEL FILTER cartridge 6............Y0602042579........cartridge water seperator 6............Y0602041296........FILTER, OIL CARTRIDGE 3............AF55014................ELEMENT AIR CLEANER primary 3............AF55308................ELEMENT AIR CLEANER safety 1............0601808803...........CIRCUIT BREAKER 1P 20A 1............0601808804...........CIRCUIT BREAKER 2P 50A 2............LY2DUS24VDC.....RELAY 1............Y0601806603........FUSE, 150A 1............0601806671...........(LEFT) 15A 1............0601802131...........FUSE, (CENTER) 1A 1............0601802133...........FUSE, (RIGHT) 5A 1............Y0601806646........FUSE, 20A NOTICE Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 53 GENERATOR ASSY. page 54 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) GENERATOR ASSY. NO. PART NO. 1 C1110100302 1-1# 1-2# 0601842334 1-3# 0601823282 1-4# 0018205020 1-4A# 0032005000 1-4B# 0401450050 1-5# 8171070002 1-6# 8171611003 1-7# C1164200004 1-8# 8171015003 1-9# 0012116045 1-10# 0042616000 1-11# 0601000209 1-12# C1112500004 1-13# 0071906314 2 M3163400603 3 Y0343204200 4 EM923344 5 012112040 6 0042512000 7 C1130000103 7- 1 0226100420 7- 2 8171323004 7- 3 0223300120 7- 4 8171323103 7- 5 0221200300 7- 6 0010110035 7- 7 031110160 7- 8 C1132200003 7- 9 0226000510 7- 10 0225000470 7- 11 0017106016 7- 12 0601850144 8 C1154000002 9 C1138000003 10 0012110065 10A 0042610000 10B 031110160 11 0017112045 12 C1154400004 13 C1154300004 14 0010106060 14A 0040006000 14B 952404470 PART NAME QTY. REMARKS ROTOR ASS'Y..........................................1.............. INCLUDES ITEMS W/# FIELD ASS'Y 1 RESISTOR 1 RECTIFIER 1 HEX. SOCKET HEAD CAP SCREW 2 WASHER, LOCK 2 WASHER, FLAT 2 FAN 1 COUPLING DISK 9 WASHER, COUPLING HUB 1 BALANCING PLATE..................................1.............. WHEN PURCHASING BALANCING ................................................................................. PLATE ITEM 1-11 MUST ALSO BE ................................................................................. ORDERED HEX. HEAD BOLT 8 WASHER, LOCK 8 BALANCING WEIGHT KIT 1 BEARING FLANGE 1 BEARING 1 COUPING RING 1 HEX. HEAD BOLT 8 WASHER, LOCK 8 HEX. HEAD BOLT 8 WASHER, LOCK 8 STATOR ASS'Y 1 RUBBER SEAL 1 CLAMPER 1 RUBBER SEAL 1 CLAMPER 1 RUBBER SEAL 1 HEX. HEAD BOLT 2 WASHER, FLAT 2 COVER 1 RUBBER SEAL 2 RUBBER SEAL 1 HEX. HEAD BOLT 6 GROMMET 1 END BRACKET 1 FIELD ASS'Y, EXCITER 1 HEX. HEAD BOLT 4 WASHER, LOCK 4 WASHER, FLAT 4 HEX. HEAD BOLT 6 COVER, BEARING 1 GASKET, BEARING 1 HEX. HEAD BOLT 4 WASHER, LOCK 4 WASHER, FLAT 4 DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 55 GENERATOR ASSY. (continued) page 56 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) GENERATOR ASSY. (continued) NO. 15 16 17 18 18-1 19 20 20A 20B 21 22 22A 23 24 25 26 27 PART NO. C1154400103 011106015 012112040 0042512000 031112230 C1132300114 0010006030 952404470 020106050 0605000012 0030020000 030220510 M3163600103 012010030 030210250 M3163700004 0070506207 PART NAME SUCTION COVER HEX. HEAD BOLT HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT COVER, FAN HEX. HEAD BOLT WASHER, FLAT NUT RUBBER SUSPENSION HEX. NUT WASHER, LOCK COUPL ING ADAPTER HEX. HEAD BOLT WASHER, LOCK SPACER, BEARING BEARING QTY. 1 8 12 12 2 1 1 1 1 2 4 4 1 12 12 1 1 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 57 control panel ASSY. page 58 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) control panel ASSY. NO. 1 2 2A 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 19 20 21 22 23 PART NO. M4223000503 M9220100004 Y0080200007 M4223000604 0017108040 0601840100 0601801040 0601801041 Y0602202642 Y0602120569 0601810171 0027104020 OEMAA8 0601831330 0601831205 82608 0601830710 0601831557 0601807642 0601808992 0601800275 0601840073 0605011211 M4246700604 M4357200202 PART NAME CONTROL PANEL SET SCREW E-RING CONTROL PANEL HEX. HEAD BOLT KNOB CHANGE-OVER SWITCH, AMMETER CHANGE-OVER SWITCH, VOLTMETER ECU CONTROLLER GAUGE UNIT ASS'Y. PANEL LIGHT, 24V MACHINE SCREW HEX. NUT PANEL LIGHT SWITCH PUSH BUTTON TOGGLE SWITCH SWITCH, PANEL LIGHT EMERGENCY STOP BUTTON FEQUENCY METER, 45~65 HZ @240V AC AMMETER, 0~400A/800A:5A AC VOLTMETER, 0~600V VOLTAGE REGULATOR, 1K OHM PIN WIRE HARNESS, GENERATOR WIRE HARNESS, ENGINE QTY. 1 2 2 1 4 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 59 CONTROL BOX ASSY. page 60 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) CONTROL BOX ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 13A 13B 14 15 15A 16 17 18 18A 18B 18C 19 20 21 22 23 24 24A 25 25-1 26 26A 27 PART NO. M4213000212 011008020 M4213400104 M4213500104 011008020 M4260500103 011008020 Y0602201456 Y0602201457 0016906016 0601821370 0027104020 LY2DUS24VDC PTF08A PYCA1 0027104020 Y0601872130 Y0601806603 0601815153 0027104020 0601802218 0601806671 0601802131 0601802133 0027103020 0601809667 0027106020 Y0801820847 0601820848 0027104020 OEMAA8 Y0601807523 Y0601827412 014210040 021112140 0601820604 PART NAME QTY. REMARKS CONTROL BOX 1 HEX. HEAD BOLT 14 BACK PANEL 1 TOP PANEL 1 HEX. HEAD BOLT 16 SET PANEL 1 HEX. HEAD BOLT 4 MAGNETIC SWITCH 1 MAGNETIC SWITCH 1 HEX. HEAD BOLT 4 RECTIFIER 2 MACHINE SCREW 2 RELAY................................................................1................REPLACES P/N 0601827655 RELAY BASE......................................................1................REPLACES P/N 0601823109 RE LAY CLIP......................................................1................REPLACES P/N 0601824400 MACHINE SCREW 2 HOLDER, FUSE 1 FUSE,150A 1 TERMINAL BLOCK 1 MACHINE SCREW 2 HOLDER, FUSE 1 FUSE (LEFT), 15A 1 FUSE (CENTER), 1A 1 FUSE (RIGHT), 5A 1 MACHINE SCREW 2 CURRENT TRANSFORMER 3 MACHINE SCREW 6 OVER CURRENT RELAY 1 OVER CURRENT RELAY 1 MACHINE SCREW 2 HEX. NUT 2 CIRCUIT BREAKER, 3P 600A 1 REAR TERMINAL BUSBAR 2 HEX. HEAD BOLT 6 SELF-LOCKING NUT 6 AUTOMATIC VOLTAGE REGULATOR 1 DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 61 CONTROL BOX ASSY. (continued) page 62 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) CONTROL BOX ASSY. (continued) NO. 28 29 30 31 32 33 34 35 36 37 38 38A 39 40 41 42 43 44 PART NO. 0027105016 M4273000003 011208030 8181852104 Y0917106025 8181853104 M4276200004 012210020 0041410000 0040010000 014210040 021112140 Y0601808646 M4213600104 952404470 505015300 0330000250 0027104020 PART NAME MACHINE SCREW TERM. BD, VOLTAGE CHANGE-OVER HEX. HEAD BOLT CHANGE TERMINAL HEX. HEAD BOLT CHANGE-OVER PLATE CHANGE PLATE TIE BOLT WASHER, FLAT WASHER, LOCK HEX. HEAD BOLT SELF-LOCKING NUT FUSE, 20A STOPPER, CONTROL PANEL WASHER, FLAT SNAP PIN EDGING MACHINE SCREW QTY. 4 1 4 10 20 6 3 26 26 26 3 3 1 1 1 1 1 2 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 63 engine AND Radiator ASSY. page 64 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) engine AND Radiator ASSY. NO. 1 1A 1-1 1-1A 1-2 1-3 1-4 2 3 4 4A 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18A 18B 19 20 20A 20B 21 22 23 24 24A 25 26 26A 27 28 29 29A 30 30A 31 PART NO. M4923200054 Y0602015246 Y0602046648 Y0602046649 RBX002252 Y0602041296 Y0602042578 M4303200603 M4303200703 0131151240 0040012000 M4357300103 Y0191701800 0605515149 Y0602022588 Y0602022579 Y0379500800 Y0603306399 Y0605511399 Y0603306597 Y0603300286 Y0602021071 Y0602012739 Y0602011024 Y0343207038 0043007000 0043107000 M4310201514 0343206120 030206150 0043106000 0016310025 Y0602013263 Y0602014823 Y0602015150 Y0605515258 Y0602014822 Y0602015151 Y0605515257 Y0602326067 Y0602013262 Y0602015152 Y0605515256 Y0602015153 Y0605515259 Y0605512198 PART NAME ENGINE, CUMMINS QSB7-G6 FAN BELT ELEMENT, AIR CLEANER, INNER ELEMENT, AIR CLEANER, OUTER AIR CLEANER INDICATER CARTRIDGE, OIL FILTER CARTRIDGE, FUEL FILTER ENGINE FOOT ENGINE FOOT HEX. HEAD BOLT WASHER, LOCK HARNESS CLAMP BLOWBY HOSE HOSE BAND ADAPTER 90° ELBOW DRAIN HOSE HOSE JOINT VALVE CONNECTOR LOCKNUT CAP RADIATOR/CAC ASS'Y CAP, RADIATOR HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT BRACKET HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT HEX. HEAD BOLT TUBE, CAC HOT SIDE TUBE, CAC COLD SIDE HOSE, HUMP CLAMP, HOSE TUBE, WATER INLET HOSE, 70-175, L=5- 00" CLAMP, HOSE U-BOLT SET TUBE, WATER OUTLET HOSE, 70-175 L=5. 00" CLAMP, HOSE HOSE, 70-100 L=52" CLAMP, HOSE HOSE JOINT QTY. 1 1 1 1 1 1 1 1 1 6 6 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 4 1 1 3 6 1 2 4 1 1 2 4 1 2 4 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 65 engine AND Radiator ASSY. (continued) page 66 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) engine AND Radiator ASSY. (continued) NO. 32 33 34 35 36 37 38 39 40 41 42 43 43A 43B 44 PART NO. Y0602015154 Y0602015155 Y0602015156 0605515198 Y0603307520 Y0605511394 Y0605512192 0193600400 Y0199101900 0605515170 Y0602211320 Y0605000010 0030012000 0040012000 M3483600104 PART NAME HOSE, 70-038 1=18" HOSE, 70-038 L=29.5" HOSE, 70-038 L=43. 5" HOSE BAND 45° ELBOW VALVE HOSE JOINT DRAIN HOSE OVER FLOW HOSE HOSE BAND COOLANT LEVEL SWITCH RUBBER SUSPENSION HEX. NUT WASHER, LOCK CLAMP QTY. 1 1 1 6 1 1 1 1 1 2 1 2 2 2 1 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 67 output terminal ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. page 68 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) output terminal ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 12A 12B 13 13A 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28-1 29 30 31 32 33 34 34A 35 36 37 38 39 40 40A 41 42 43 44 45 46 PART NO. C1231700003 M9220100304 0801830804 3461860504 0039316000 0040016000 0401450160 0016908040 M4236100403 0016906016 0605010040 0027103010 0207003000 0041203000 0027103015 0207003000 M4236100504 M9220100804 0040006000 952404470 0080200005 M4236100703 0805009804 012212045 031112230 0030012000 0605011505 0027105016 M4236400204 0016906016 M4260600104 0222100150 011206020 0601808803 0601808804 Y0601814014 0601814013 7538070 OEMAA8 0601850275 0601815194 7538070 0603306775 7538070 0017110025 0040510000 M4236100604 M4236400304 0016906016 M4236400004 M4236400104 011206020 PART NAME TERMINAL BOARD OUTPUT TERMINAL BOLT TIE BOLT TERMINAL PLATE HEX. NUT WASHER, LOCK WASHER, FLAT HEX. HEAD BOLT TERMINAL COVER HEX. HEAD BOLT HINGE MACHINE SCREW HEX. NUT WASHER, FLAT MACHINE SCREW HEX. NUT OUTPUT WINDOW SET SCREW WASHER, LOCK WASHER, FLAT RING TERMINAL COVER STAY RUBBER HEX. HEAD BOLT WASHER, FLAT HEX. NUT STAY MACHINE SCREW COVER HEX. HEAD BOLT BRACKET, CIRCUIT BREAKER RUBBER CUSHION HEX. HEAD BOLT CIRCUIT BREAKER, 1P, 20A CIRCUIT BREAKER, 2P, 50A RECEPTACLE, CS-6369L, 50A RECEPTACLE, GF-20LA, 20A MACHINE SCREW HEX. NUT GROMMET TERMINAL BLOCK MACHINE SCREW BLIND PLUG MACHINE SCREW HEX. HEAD BOLT TOOTHED WASHER INSULATING COVER BRACKET HEX. HEAD BOLT CABLE OUTLET COVER SUPPORTER, CABLE OUTLET COVER HEX. HEAD BOLT QTY. 1 8 8 3 16 24 32 5 1 4 2 4 4 4 4 4 1 2 2 2 2 1 2 2 4 2 1 4 1 8 1 1 2 2 3 3 2 10 10 I 1 2 2 4 1 1 1 1 2 1 1 8 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 69 battery ASSY. page 70 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) battery ASSY. NO. PART NO. 1 0602220199 2 M9103000804 3 0602220920 3A# 3B# 4 M9310500014 5 M4346900404 6 M3346902104 7 M4346900504 8 020108060 9 0040508000 10 0016910025 11 0040510000 12 PART NAME QTY. REMARKS BATTERY 2 BATTERY BAND 1 BATTERY BOLT SET..........................................2 ...............INCLUDES ITEMS W/# WING NUT 2 PLASTIC WASHER 2 BATTERY SHEET 2 BATTERY CABLE 1 BATTERY CABLE 1 BATTERY CABLE 1 HEX. NUT 1 TOOTHED WASHER 1 HEX. HEAD BOLT 1 TOOTHED WASHER 1 EARTH CABLE...................................................1................MAKE LOCALLY DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 71 muffler ASSY. page 72 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) muffler ASSY. NO. 1 2 3 4 5 6 7 8 8A 9 9A 10 11 12 13 14 15 16 17 18 19 20 21 PART NO. Y0602300240 M4330400003 0016910025 M2330400704 011008020 0207308000 M4333000503 Y0602325039 Y0602320129 Y0602325038 Y0602320128 M3330400804 M3330400903 011008020 0602326062 M4333100004 M4357300014 011008020 0601851736 Y0602311130 0605515225 0602220911 0016910025 PART NAME DEVICE, AFTER TREATMENT BRACKET HEX. HEAD BOLT BAND HEX. HEAD BOLT SUPER LOCK NUT EXHAUST PIPE V-BAND CLAMP GASKET V-BAND CLAMP GASKET EXHAUST PIPE COVER EXHAUST PIPE BRACKET HEX. HEAD BOLT U-BOLT SET EXHAUST TAIL PIPE HARNESS CLAMP HEX. HEAD BOLT GROMMET EXHAUST INSULATING WRAP HOSE BAND CLAMP HEX. HEAD BOLT QTY. 1 1 4 2 2 2 1 1 1 1 1 1 1 4 1 1 1 2 1 1 4 1 1 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 73 fuel tank ASSY. page 74 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) fuel tank ASSY. NO. 1 1-1 2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 17 18 18A PART NO. M4363000202 0605505070 M4363200004 M9310500104 011008020 0207308000 0191302300 Y0191204000 0605515109 Y0602042579 014210040 Y0602022578 Y0602022985 0602220911 0016906016 M1363400104 0605515198 1502025103C 011206020 0802011104 0150000018 PART NAME FUEL TANK FUEL TANK CAP TANK BAND SUPPORTER SHEET HEX. HEAD BOLT SUPER LOCK NUT SUCTION HOSE RETURN HOSE HOSE BAND CART., FUEL WATER SEPARATOR HEX. HEAD BOLT 90° ELBOW HOSE JOINT CLAMP HEX. HEAD BOLT DRAIN HOSE HOSE BAND DRAIN JOINT HEX. HEAD BOLT DRAIN BOLT O-RING QTY. 1 1 2 4 2 2 1 1 4 1 2 1 1 1 1 1 2 1 2 1 1 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 75 ENCLOSURE ASSY. page 76 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) ENCLOSURE ASSY. NO. 1 2 3 4 4A 5 5A 6 7 8 8A 9 10 11 12 13 13A 13B 13C 14 14A 14B 14C 15 15A 16 17 17A 18 19 19A 20 21 22 22A 23 PART NO. M4413000412 M1413400004 011008020 M4423000512 M4493104603 M4423000602 M4493104603 011008020 0016910025 M4423200004 M4493100004 0019208020 M4423200503 0019208020 M4433000212 0010114040 030214350 031114260 515455840 0010120050 030220510 0041220000 0030020000 M4443000202 M4493302804 0016910025 M4443300404 M4493302904 0019208020 M4443300503 M4493303004 020108060 M4443200403 M9110100204 M9116100004 0845031504 PART NAME BASE COVER HEX. HEAD BOLT FRONT FRAME ACOUSTIC SHEET FRONT FRAME ACOUSTIC SHEET HEX. HEAD BOLT HEX. HEAD BOLT COVER, FRONT FRAME ACOUSTIC SHEET HEX. HEAD BOLT TOP COVER, FRONT FRAME HEX. HEAD BOLT CENTER FRAME HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT HEX. NUT HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT HEX. NUT REAR FRAME ACOUSTIC SHEET HEX. HEAD BOLT COVER, REAR FRAME ACOUSTIC SHEET HEX. HEAD BOLT DUCT, REAR FRAME ACOUSTIC SHEET HEX. NUT DOOR, REAR FRAME HINGE WASHER BLIND PLUG QTY. 1 1 2 I 1 1 1 10 10 1 1 22 1 15 1 4 4 8 4 4 4 8 4 1 1 4 1 1 14 1 1 9 1 2 2 2 REMARKS ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 77 ENCLOSURE ASSY. (cont.) page 78 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) ENCLOSURE ASSY. (cont.) NO. 24 25 26 27 28 28A 29 30 31 32 32A 33 33A 34 35 36 37 37A 38 39 40 41 42 42A 43 44 45 46 46A 47 47A 47B 48 48A 49 49A PART NO. 0019208020 0601850097 0027208025 M4443600004 020106050 952404470 0600800320 0021806016 M9114000002 0021806016 020106050 M4463100302 M4493503004 0019208020 M3310600004 0019208020 M4463200502 M4493503103 0019208020 0017110025 M4463200304 Y0016908016 M4463200603 M4493503204 0016908020 M4463500204 0019206015 M4453200202 M4493403604 0019108065 0042308000 031108160 M4453001403 M4493407404 M4453001503 M4493407504 PART NAME HEX. HEAD BOLT STOPPER MACHINE SCREW WINDOW PLATE SELF-LOCKING J NUT WASHER, FLAT MANUAL PACK MACHINE SCREW DOOR HANDLE MACHINE SCREW HEX. NUT ROOF PANEL ACOUSTIC SHEET HEX. HEAD BOLT COVER HEX. HEAD BOLT ROOF PANEL ACOUSTIC SHEET HEX. HEAD BOLT HEX. HEAD BOLT COVER HEX. HEAD BOLT DUCT, REAR ROOF ACOUSTIC SHEET HEX. HEAD BOLT GUTTER HEX. HEAD BOLT SPLASHER PANEL ACOUSTIC SHEET HEX. HEAD BOLT WASHER, LOCK WASHER, FLAT SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET QTY. 3 1 1 1 8 8 1 4 1 4 4 1 1 10 1 4 1 1 16 4 2 12 1 1 10 2 8 1 1 6 6 6 1 1 1 1 REMARKS ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 79 ENCLOSURE ASSY. (cont.) page 80 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) ENCLOSURE ASSY. (cont.) NO. 50 50A 51 51A 52 52A 53 53A 54 54A 55 55A 56 57 58 59 59A 60 61 62 63 63A 64 64A 65 66 67 68 PART NO. M4453001603 M4493407604 M4453001703 M4493407704 M4453301104 M4493407804 M4453301204 M4493407904 M4453301304 M4493408004 M4453301404 M4493408104 020108060 M9114000002 M9113000102 0021806018 020106050 M4453600004 M4453600104 0019206015 0845046904 M9116100004 0845047004 M9116100004 0019208020 0601850097 0027208025 0845031504 PART NAME SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX. NUT DOOR HANDLE DOOR HANDLE MACHINE SCREW HEX. NUT GUTTER GUTTER HEX. HEAD BOLT HINGE WASHER HINGE WASHER . HEX. HEAD BOLT STOPPER MACHINE. SCREW BLIND PLUG QTY. 1 1 1 1 3 3 1 1 1 1 1 1 36 4 3 28 28 3 3 18 5 5 6 6 25 8 8 11 REMARKS ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 6-CATERPILLAR YELLOW 2-WHITE 7-CATO GOLD 3-SPECTRUM GREY 8-RED 4-SUNBELT GREEN 9-DESERT TAN 5-BLACK THE SERIAL NUMBER MAY BE REQUIRED. DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 81 rubber seals ASSY. page 82 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) rubber seals ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO. 0229201300 0229201200 0228901120 0228901260 0228900660 0228900795 0228901055 0228901200 0228900600 0229400630 0228801050 0228800590 0228100560 0228100370 0222100120 0222100180 PART NAME SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER RUBBER SHEET RUBBER SHEET QTY. 4 1 1 3 1 4 4 3 1 1 2 1 2 2 2 2 REMARKS DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 83 nameplate and decals ASSY. page 84 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) nameplate and decals ASSY. NO. 1-1 1-2 1-3 1-4 PART NO. M4550000603 M4550000703 M9520100304 M9520100603 PART NAME QTY. REMARKS DECAL: OPERATING PROCEDURES..............1.................M45000060 DECAL: DPF REGEN. PROCEDURES.............1.................M45000070 DECAL: SAFETY INSTRUCTIONS...................1.................M92010030 DECAL: CAUTION.............................................2.................M92010060 2-1 M4550000402 2-2 M9520000104 2-3 M9520000204 2-4 M9520100004 2-5 M9520100704 2-6 M9520200404 2-7 M9522000504 2-8 M9520200303 2-9 M9520200504 CONTROL PANEL AND BOX GROUP................................ DECAL: CONTROL PANEL...............................1.................M4S000040 PLATE: AMMETER CHANGE-OVER SW..........1.................M92000010 PLATE: VOLTMETER CHANGE-OVER SW.......1.................M92000020 DECAL: WARNING, ELECT. SHOCK HAZ........2.................M92010000 DECAL: WARNING, ARC FLASH......................1.................M92010070 DECAL; OVER CURRENT RELAY....................1.................M92020040 DECAL: CIRCUIT BREAKER............................1.................M92200050 DECAL: SET FOR OUTPUT VOLTAGE.............1.................M92020030 DECAL: SET FOR OUTPUT VOLTAGE (S) ......1.................M92020050 3-1 M9500000004 3-2 M9500100004 3-3 M9503000004 3-4 M9503000103 3-5 M9503100004 3-6 M9510100004 ENGINE AND RADIATOR GROUP.................... DECAL: 0IL DRAIN PLUG.................................1.................M90000000 DECAL: WATER.................................................1.................M90010000 DECAL: WARNING, ROTATING PART..............2.................M90300000 DECAL: WATER OIL CHECK............................1.................M90300010 DECAL: WARNING, HOT COOLANT................1.................M90310000 DECAL: CAUTION, HOT PARTS .....................1.................M91010000 4-1 M4550000503 4-2 M9520000004 4-3 M9520000504 4-4 M9520000704 4-5 M9520100404 4-6 M9520100503 MOUNT TERMINAL GROUP............................. DECAL: RECEPT. AND CB................................1.................M45000050 DECAL: GROUND.............................................2.................M92000000 DECAL: START CONTACT ..............................1.................M92000050 DECAL: 3-PHASE OUTPUT TERMINAL...........1.................M92000070 DECAL: DANGER, HIGH VOLTAGE..................1.................M92010040 DECAL: WARNING............................................1.................M92010050 5-1 M9500300004 5-2 M9500300104 5-3 M9510100403 6-1 M9503200004 6-2 M9503200104 6-3 M9504200004 7-1 M9501500004 7-2 M9500500104 BATTERY GROUP............................................. DECAL: -............................................................1.................M90030000 DECAL:+............................................................1.................M90030010 DECAL: CAUTION.............................................1.................M91010040 MUFFLER GROUP............................................................... DECAL: WARNING, ENGINE EXHAUST..........1.................M90320000 DECAL: DANGER, EXHAUST...........................1.................M90320010 DECAL: WARNING, START FIRES...................1.................M90420000 FUEL TANK GROUP........................................... DECAL: DIESEL FUEL......................................2.................M90150000 DECAL: FUEL DRAIN PLUG.............................1.................M90050010 DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 85 nameplate and decals ASSY. (cont.) page 86 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) nameplate and decals ASSY. (cont.) NO. PART NO. 8-1 M9510200002 8-2 0600500090 8-2A 0021106016 8-3 M4560100704 8-4 M4560101404 8-5 M4560101504 8-6 M4560101603 8-7 M4560100003 8-8 M4560101703 8-9 M3550002204 8-10 M9512000004 8-11 M9510000104 PART NAME QTY. REMARKS ENCLOSURE GROUP DECAL: MQ........................................................1................M91020000 EMBLEM 2 MACHINE SCREW 4 STRIPE...............................................................2................M46010070 STRIPE...............................................................1................M46010140 STRIPE...............................................................2................M46010150 STRIPE...............................................................2................M46010160 STRIPE...............................................................1................M46010000 STRIPE...............................................................1................M46010170 DECAL: CAUTION..............................................1................M35000220 DECAL: SUPPORT HOOK ...........................2................M91200000 DECAL: DOCUMENT BOX LOCATED...............1................M91000010 DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 87 Terms and Conditions of Sale — Parts PAYMENT TERMS 5. Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked. 6. The following items are not returnable: Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products. a. SPECIAL EXPEDITING SERVICE Terms of payment for parts are net 30 days. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier. b. MINIMUM ORDER The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement. RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed, subject to the following provisions: 1. A Returned Material Authorization must be approved by Multiquip prior to shipment. 2. Obsolete parts. (If an item is in the price book and shows as being replaced by another item, it is obsolete.) Any parts with a limited shelf life (such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date. c. Any line item with an extended dealer net price of less than $5.00. d. Special order items. e. Electrical components. f. Paint, chemicals, and lubricants. g. Decals and paper products. h. Items purchased in kits. 7. The sender will be notified of any material received that is not acceptable. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned. 8. Such material will be held for five working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense. a. The parts numbers and descriptions must match the current parts price list. 9. b. The list must be typed or computer generated. Credit on returned parts will be issued at dealer net price at time of the original purchase, less a 15% restocking charge. c. The list must state the reason(s) for the return. d. The list must reference the sales order(s) or invoice (s) under which the items were originally purchased. e. The list must include the name and phone number of the person requesting the RMA. 3. A copy of the Return Material Authorization must accompany the return shipment. 4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point. 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. A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier. LIMITATIONS OF SELLER’S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages. LIMITATION OF WARRANTIES No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof. Effective: February 22, 2006 11. Credit issued will be applied to future purchases only. PRICING AND REBATES Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change. page 88 — dca220sscu/4i 60 hz generator • operation and Parts manual — rev. #0 (10/25/12) notes DCA220ssCU/4i 60 hz generator• operation manual — rev. #0 (10/25/12) — page 89 Operation Manual HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING United StateS Multiquip Corporate Office 18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com MQ Parts Department Tel. (800) 421-1244 Fax (310) 537-3927 Service Department 800-421-1244 310-537-3700 800-427-1244 310-537-3700 Fax: 800-672-7877 Fax: 310-637-3284 Warranty Department Fax: 310-537-4259 800-421-1244 310-537-3700 Fax: 310-943-2249 Technical Assistance 800-478-1244 Fax: 310-943-2238 mexico United Kingdom MQ Cipsa Multiquip (UK) Limited Head Office Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: pmastretta@cipsa.com.mx Tel: (52) 222-225-9900 Fax: (52) 222-285-0420 Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinfield, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk Tel: 0161 339 2223 Fax: 0161 339 3226 Canada Multiquip 4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: jmartin@multiquip.com Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664 © COPYRIGHT 2012, MULTIQUIP INC. Multiquip Inc, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission. This manual MUsT accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations. Your Local Dealer is:
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