Multiquip Dca220Sscu Users Manual

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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

®

WHISPERWATT™ SERIES

MODEL DCA220SSCU

MODEL DCA220SSCU4i

60Hz GENERATOR

(CUMMINS QSB7-G6 DIESEL ENGINE)

PARTS LIST NO. M4870300204

Revision #0 (10/25/12)

OPERATION AND PARTS MANUAL

PAGE 2 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 3

If you believe that your vehicle has a defect that could cause a crash or could cause

injury or death, you should immediately inform the National Highway Traffic Safety

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

If NHTSA receives similar complaints, it may open an investigation, and if it finds

that a safety defect exists in a group of vehicles, it may order a recall and remedy

campaign. However, NHTSA cannot become involved in individual problems

between you, your dealer, or Multiquip.

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

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

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from

http://www.safecar.gov.

REPORTING SAFETY DEFECTS

PAGE 4 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 5

NOTES

PAGE 6 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

SAFETY MESSAGES

The four safety messages shown below will inform you

about potential hazards that could injure you or others. The

safety messages specifi cally address the level of exposure

to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

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.

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 7

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 infl uence of

drugs or alcohol.



ALWAYS check the equipment for loosened threads or

bolts before starting.



DO NOT use the equipment for any purpose other than

its intended purposes or applications.

NOTICE



This equipment should only be operated by trained and

qualifi ed personnel 18 years of age and older.



Whenever necessary, replace nameplate, operation and

safety decals when they become diffi cult read.



Manufacturer does not assume responsibility for any

accident due to equipment modifi cations. Unauthorized

equipment modifi cation will void all warranties.

NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

to the equipment and/or injury to user may result.

ALWAYS know the location of the nearest

fi re extinguisher.

ALWAYS know the location of the nearest

fi rst aid kit.

ALWAYS know the location of the nearest

phone or keep a phone on the job site.

Also, know the

phone numbers of the nearest ambulance, doctor

and

fi re department.

This information will be invaluable in

the case of an emergency.

GENERATOR SAFETY

DANGER

NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An

explosion or fi re could result causing severe

bodily harm or even death.

WARNING

NEVER disconnect any

emergency or safety devices.

These devices are intended for operator safety.

Disconnection of these devices can cause severe injury,

bodily harm or even death. Disconnection of any of these

devices will void all warranties.

CAUTION

NEVER lubricate components or attempt service on a

running machine.

NOTICE

ALWAYS

ensure generator is on level ground before use.

ALWAYS

keep the machine in proper running condition.

Fix damage to machine and replace any broken parts

immediately.

ALWAYS

store equipment properly when it is not being

used. Equipment should be stored in a clean, dry location

out of the reach of children and unauthorized personnel

PAGE 8 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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

fl ow of cooling air. NEVER

operate this equipment in

any enclosed or narrow area

where free fl ow of the air is

restricted. If the air fl ow is

restricted it will cause injury to people and property and

serious damage to the equipment or engine.

WARNING

DO NOT place hands or fingers inside engine

compartment when engine is running.

NEVER operate the engine with heat shields or

guards removed.



Keep fi ngers, hands hair and clothing away

from all moving parts to prevent injury.



DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water

will gush out of the radiator and severely

scald any persons in the general area of

the generator.

DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and

severely scald any persons in the general area of the

generator.

DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and

severely scald any persons in the general area of the

generator.

CAUTION



NEVER touch the hot exhaust manifold,

muffl er or cylinder. Allow these parts to cool

before servicing equipment.

NOTICE

NEVER

run engine without an air fi lter or with a dirty air

fi lter. Severe engine damage may occur. Service air fi lter

frequently to prevent engine malfunction.

NEVER tamper with the factory settings

of the engine or engine governor. Damage

to the engine or equipment can result

if operating in speed ranges above the

maximum allowable.



Wet stacking is a common problem with diesel engines

which are operated for extended periods with light or

no load applied. When a diesel engine operates without

suffi cient load (less than 40% of the rated output), it will

not operate at its optimum temperature. This will allow

unburned fuel to accumulate in the exhaust system,

which can foul the fuel injectors, engine valves and

exhaust system, including turbochargers, and reduce

the operating performance.

In order for a diesel engine to operate at peak effi ciency,

it must be able to provide fuel and air in the proper ratio

and at a high enough engine temperature for the engine

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

applied to relieve the condition. It can reduce the system

performance and increase maintenance. Applying an

increasing load over a period of time until the excess

fuel is burned off and the system capacity is reached

usually can repair the condition. This can take several

hours to burn off the accumulated unburned fuel.

State Health Safety Codes and Public Resources

Codes specify that in certain locations, spark arresters

must be used on internal combustion engines that use

hydrocarbon fuels. A spark arrester is a device designed

to prevent accidental discharge of sparks or fl ames

from the engine exhaust. Spark arresters are qualifi ed

and rated by the United States Forest Service for this

purpose. In order to comply with local laws regarding

spark arresters, consult the engine distributor or the

local Health and Safety Administrator.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 9

SAFETY INFORMATION

FUEL SAFETY

DANGER

DO NOT start the engine near spilled fuel or combustible

fl uids. Diesel fuel is extremely fl ammable and its vapors

can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from

sparks and open fl ames.

ALWAYS use extreme caution when working with

fl ammable liquids.

DO NOT fi ll the fuel tank while the engine is running

or hot.

DO NOT overfi ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from

the ignition system.

Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and fl ames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the

equipment. Fire or explosion could result

from fuel vapors or if fuel is spilled on a

hot engine.

TOWING SAFETY

CAUTION

Check with your local county or state safety

towing regulations, in addition to meeting

Department of Transportation (DOT)

Safety Towing Regulations, before towing

your generator.

Refer to MQ Power trailer manual for additional safety

information.

In order to reduce the possibility of an accident while

transporting the generator on public roads, ALWAYS

make sure the trailer that supports the generator and

the towing vehicle are mechanically sound and in good

operating condition.

 ALWAYS shutdown engine before transporting

Make sure the hitch and coupling of the towing vehicle

are rated equal to, or greater than the trailer “gross

vehicle weight rating.”

ALWAYS inspect the hitch and coupling for wear.

NEVER

tow a trailer with defective hitches, couplings, chains, etc.

Check the tire air pressure on both towing vehicle and

trailer.

Trailer tires should be infl ated to 50 psi cold.

Also check the tire tread wear on both vehicles.

ALWAYS make sure the trailer is equipped with a

safety

chain.

ALWAYS properly

attach trailer’s safety chains to towing

vehicle.

ALWAYS

make sure the vehicle and trailer directional,

backup, brake and trailer lights are connected and

working properly.

DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie

wraps.

The maximum speed for highway towing is 55 MPH

unless

posted otherwise. Recommended off-road towing is not to

exceed 15 MPH or less depending on type of terrain.



Avoid sudden stops and starts. This can cause skidding,

or jack-knifi ng. Smooth, gradual starts and stops will

improve towing.

Avoid sharp turns to prevent rolling.



Trailer should be adjusted to a level position at all times

when towing.

Raise and lock trailer wheel stand in up position when

towing.

Place chock blocks underneath wheel to prevent

rolling

while parked.

Place support blocks

underneath the trailer’s bumper

to prevent tipping while parked.



Use the trailer’s swivel jack to adjust the trailer height to

a level position while parked.

PAGE 10 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

Power Cord/Cable Safety

DANGER

NEVER let power cords or cables lay in water.

NEVER stand in water while AC power from the

generator is being transferred to a load.

NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in

the insulation.



NEVER grab or touch a live power

cord or cable with wet hands. The

possibility exists of electrical shock,

electrocution or death.

Make sure power cables are securely connected to the

generator’s output receptacles. Incorrect connections

may cause electrical shock and damage to the

generator.

NOTICE

ALWAYS

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

Chart in this manual.

Grounding Safety

DANGER

ALWAYS

make sure that electrical circuits are properly

grounded to a suitable earth ground (ground rod) per

the National Electrical Code (NEC) and local codes

before operating generator.

Severe injury or death by

electrocution

can result from operating an ungrounded

generator.

NEVER use gas piping as an electrical ground.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 11

SAFETY INFORMATION

BATTERY SAFETY

DANGER

DO NOT drop the battery. There is a possibility that the

battery will explode.

DO NOT expose the battery to open fl ames,

sparks, cigarettes, etc. The battery contains

combustible gases and liquids. If these

gases and liquids come into contact with a

fl ame or spark, an explosion could occur.

WARNING

ALWAYS wear safety glasses when handling

the battery to avoid eye irritation. The battery

contains acids that can cause injury to the

eyes and skin.

Use well-insulated gloves when picking up the battery.

ALWAYS keep the battery charged. If the battery is not

charged, combustible gas will build up.

ALWAYS recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration

of combustible gasses.

If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing

immediately with plenty of water.

If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty

of water and contact the nearest doctor or hospital to

seek medical attention.

CAUTION

ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

ENVIRONMENTAL SAFETY

NOTICE

Dispose of hazardous waste properly.

Examples of potentially hazardous waste

are used motor oil, fuel and fuel fi lters.

DO NOT use food or plastic containers to

dispose of hazardous waste.

DO NOT

pour waste, oil or fuel directly onto the ground,

down a drain or into any water source.

PAGE 12 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

SPECIFICATIONS

Table 1. Generator Specifications

Model DCA220SSCU/ DCA220SSCU4i

Type Revolving field, self ventilated,

open protected type synchronous generator

Armature Connection Star with Neutral

Phase 3

Standby Output 194 kW (242 kVA)

Prime Output 176 kW (220 kVA)

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 240/139 208Y/120, 220Y/127, 240Y/139

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 480/277 416Y/240, 440Y/254, 480Y/277

1Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 1Ø 240/120 240/120

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

Type 4 cycle, water-cooled, direct injection, turbo-charged

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)

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

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

Battery 27 (CCA 0°F 800A) X 2

1 Includes engine and radiator hoses

2 Includes filters

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 13

DIMENSIONS

SIDE VIEW

TOP VIEW

FRONT VIEW

G

H

F

A E

BC

D

MAXIMUM

LIFTING

POINT

14,050 lbs.

(6,373 kg)

220

Table 3. Dimensions

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)

Figure 1. Dimensions

PAGE 14 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

INSTALLATION

Figure 2. Typical Generator Grounding Application

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 15

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris,

bystanders, and overhead obstructions. Make sure the

generator is on secure level ground so that it cannot slide

or shift around. Also install the generator in a manner so

that the exhaust will not be discharged in the direction of

nearby homes.

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

of the insulation and will result in short circuits and

grounding.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to

engine and alternator parts.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely

poisonous. Whenever an engine is installed indoors the

exhaust fumes must be vented to the outside. The engine

should be installed at least two feet from any outside wall.

Using an exhaust pipe which is too long or too small can

cause excessive back pressure which will cause the engine

to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such

as concrete) and set firmly on the foundation to isolate

vibration of the generator when it is running. The generator

must set at least 6 inches above the floor or grade level (in

accordance to NFPA 110, Chapter 5-4.1). DO NOT remove

the metal skids on the bottom of the generator. They are

to resist damage to the bottom of the generator and to

maintain alignment.

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.

GENERATOR GROUNDING

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground (Figure 2).

Article 250 (Grounding) of the National Electrical Code

(NEC) provides guide lines for proper grounding and

specifies that the cable ground shall be connected to the

grounding system of the building as close to the point of

cable entry as practical.

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

grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.

a. Copper - 8 AWG (5.3 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.

NOTICE

When connecting the generator to any buildings

electrical system ALWAYS consult with a licensed

electrician.

NOTICE

This generator has a permanent bonding conductor

between the generator stator windings and the frame.

PAGE 16 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

GENERATOR

This generator (Figure 3) is designed as a high quality

portable (requires a trailer for transport) power source for

telecom sites, lighting facilities, power tools, submersible

pumps and other industrial and construction machinery.

OPERATING PANEL

The “Operating Panel” is provided with the following:

ECU Controller

Gauge Unit Assembly

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge

• Tachometer

Panel Light/Panel Light Switch

Hour Check Button

Auto Start/Stop Switch

Engine Speed Switch

Emergency Stop Button

Water Temperature Gauge

CONTROL PANEL

The “Control Panel” is provided with the following:

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Voltage Regulator

3-Pole, 600 amp Main Circuit Breaker

“Control Box” (located behind Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

OUTPUT TERMINAL PANEL

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

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

Three auxiliary circuit breakers, 50A

Two 120V output receptacles (GFCI), 20A

Two GFCI circuit breakers, 20A

Eight output terminal lugs (3Ø power)

Ground lug

Battery Charger (Optional)

Jacket Water Heater (Optional)

OPEN DELTA EXCITATION SYSTEM

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

Delta” excitation system. The open delta system consist

of an electrically independent winding wound among

stationary windings of the AC output section.

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

D. During steady state loads, the power from the voltage

regulator is supplied from the parallel connections of A to

B, A to D, and C to D. These three phases of the voltage

input to the voltage regulator are then rectified and are the

excitation current for the exciter section.

When a heavy load, such as a motor starting or a short

circuit occurs, the automatic voltage regulator (AVR)

switches the configuration of the open delta to the series

connection of B to C. This has the effect of adding the

voltages of each phase to provide higher excitation to the

exciter section and thus better voltage response during the

application of heavy loads.

The connections of the AVR to the AC output windings are

for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation

current, offering maximum motor starting capabilities. The

excitation does not have a “fixed ceiling” and responds

according the demands of the required load.

ENGINE

This generator is powered by a 6 cylinder, 4-cycle water

cooled, direct injection, turbocharged, air cooled Cummins

QSB7-G6 diesel engine. This engine is designed to

meet every performance requirement for the generator.

Reference Table 2 for engine specifications.

In keeping with MQ Power’s policy of constantly improving

its products, the specifications quoted herein are subject

to change without prior notice.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine.

When the engine demand increases or decreases, the

governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or

loads at some distance from the generator, extension cords

are normally used. Cables should be sized to allow for

distance in length and amperage so that the voltage drop

between the generator and point of use (load) is held to

a minimum. Use the cable selection chart (Table 6) as a

guide for selecting proper extension cable size.

GENERAL INFORMATION

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 17

MAJOR COMPONENTS

220

220

UVWOGND

Denyo

OFF

W

U

V

OFF

W-U

V-W

U-V

DECREASE

INCREASE

PSI

OILPRESS

0

25 50 75

100 °F

WATERTEMP

100

140 180 220

260 VOLTS

BATTERY

6

12 18 24

30

FUEL

E

½

FRPMX10

SPEED

0

120 150 180

210

60

Engine Started

Shutdown

Pre-Alarm

Series 800 Controller

Alarm

Acknowledge

Screen

Change

Program/

Exit

Option

ECU

12

3

4

56

7

8

11

9

10

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

PAGE 18 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENGINE CONTROL UNIT (ECU)

Figure 4. Engine Control Unit (ECU)

PSI

OIL PRESS

0

25 50 75

100 °F

WATERTEMP

100

140 180 220

260 VOLTS

BATTERY

6

12 18 24

30

°F

FUEL

E

½

FRPMX10

SPEED

0

120 150 180

210

60

Series 800 Controller

ECU

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Program

Exit

Option

OFF

U-V W-U

V-W

OFF

V

W

U

INCREASE DECREASE

Series 800 Controller

ECU

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Program

Exit

Option

A

B

C

D

E F GH

1

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 19

ENGINE/GENERATOR CONTROL PANEL

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

PSI

OIL PRESS

0

25 50 75

100 °F

WATER TEMP

100

140 180 220

260 VOLTS

BATTERY

6

12 18 24

30

°F

FUEL

E

½

FRPMX10

SPEED

0

120 150 180

210

60

D

AB C

E

1

PSI

OIL PRESS

0

25 50 75

100 °F

WATERTEMP

100

140 180 220

260 VOLTS

BATTERY

6

12 18 24

30

°F

FUEL

E

½

FRPMX10

SPEED

0

120 150 180

210

60

Series 800 Controller

ECU

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Program

Exit

Option

OFF

U-V W-U

V-W

OFF

V

W

U

INCREASE DECREASE

7

4

5

6

8

9

10

11

13 12

23

14

Figure 5. Gauge Unit Assembly

5. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by

the ammeter phase-selector switch.

6. AC Voltmeter — Indicates the output voltage present

at the U,V, and W Output Terminal Lugs.

7. Voltage Regulator Control — Allows ±15% manual

adjustment of the generator’s output voltage.

8. Ammeter Change-Over Switch — This switch allows

the AC ammeter to indicate the current flowing to the load

connected to any phase of the output terminals, or to be

switched off. This switch does not effect the generator

output in any fashion, it is for current reading only.

9. Voltmeter Change-Over Switch — This switch allows

the AC voltmeter to indicate phase to phase voltage

between any two phases of the output terminals or to

be switched off.

10. Emergency Stop Button — Push this button inward

to stop the engine in the event of an emergency. DO

NOT use this button as a means of stopping the engine.

11. Engine Speed Switch — This switch controls the

speed of the engine (low/high).

12. Auto/Start Switch — This switch selects either manual

or automatic operation . Center position is OFF (reset).

13. Hour Check Button — With the engine stopped, press

and hold ths button. The total running hours, fuel level,

and battery voltage will be displayed.

14. Main Circuit Breaker — This three-pole, 600 amp

main breaker is provided to protect the U,V, and W

Output Terminal Lugs from overload.

PAGE 20 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 7) shown below is

located on the right-hand side (left from control panel) of

the generator. Lift up on the cover to gain access to

receptacles and terminal lugs.

NOTICE

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

grounds

OUTPUT TERMINAL FAMILIARIZATION

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

the following:

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

Three (3) Circuit Breakers @ 50 amps

Two (2) 120V GFCI receptacles @ 20 amp

Two (2) GFCI Circuit Breakers @ 20 amps

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

AUX. POWER RECEPTACLES

240/139V, 50 AMPS

120 VAC, 20 AMP

GFCI RECEPTACLES

Y

X

W

CS-6369

TWIST-LOCK

CIRCUIT BREAKERS

FOR CS-6369 TWIST

LOCK RECEPTACLES

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

O

UVW

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

NEUTRAL

TERMINAL GROUND

TERMINAL

HARD WIRE

HOOKUP PANEL

BLACK RED BLUE WHITE GREEN

Figure 6. Output Terminal Panel

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 21

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.

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

Twist Lock Dual Voltage 120/240 VAC Receptacles

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

6369) receptacles (Figure 8) provided on the output

terminal panel. These receptacles can only be accessed

when the voltage change-over board is configured for

single-phase 240/120 application

Figure 8. 240/139V Twist-Lock Auxiliary

Receptacles

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

PAGE 22 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the Output

Terminal Lugs or the convenience receptacles (Figure 10).

Make sure to read the operation manual before attempting

to connect a load to the generator.

To protect the output terminals from overload, a 3-pole,

600A main circuit breaker is provided. Make sure to switch

ALL circuit breakers to the OFF position prior to starting

the engine.

Figure 10. Connecting Loads

Over Current Relay

An over current relay (Figure 11) is connected to the main

circuit breaker. In the event of an overload, both the circuit

breaker and the over current relay may trip. If the circuit

breaker can not be reset, the reset button on the over

current relay must be pressed. The over current relay is

located in the control box.

Figure 11. Over Current Relay

NOTICE

Remember the overcurrent relay monitors the current

flowing from the U,V, and W Output Terminal Lugs

to the load.

In the event of a short circuit or over current condition,

it will automatically trip the 600 amp main breaker.

To restore power to the Output Terminal Panel, press

the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 23

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage, frequency,

and voltage requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require

130—150% more wattage than the rating on the nameplate,

as the wattage is influenced by the efficiency, power factor

and starting system of the equipment.

WATTS = VOLTAGE x AMPERAGE

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

when connecting loads.

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

in

Amperes

Load in Watts Maximum Allowable Cable Length

At 100

Volts

At 200

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

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 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.

20 2400 4800 125 ft. 75 ft. 50 ft.

CAUTION: Equipment damage can result from low voltage

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.

Table 5. Power Factor By Load

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication

equipment 1.0

Common power tools 0.8

THREE PHASE LOAD

When calculating the power requirements for 3-phase

power use the following equation:

An inadequate size connecting cable which cannot carry the

required load can cause a voltage drop which can burn out

the appliance or tool and overheat the cable. See Table 6.

When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up

to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW)

multiplied by 0.6 can be used.

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

NOTICE

If 3Ø load (kVA) is not given on the equipment

nameplate, approximate 3Ø load may be determined

by multiplying voltage by amperage by 1.732

NOTICE

Motors and motor-driven equipment draw much greater

current for starting than during operation.

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.

PAGE 24 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage

for many different applications. Voltages are selected by

applying jumpers (6) to the voltage change-over board

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

Table 7 (see below) will require a fine adjustment using

the voltage regulator (VR) control knob located on the

control panel.

Voltage Change-Over Board

The voltage change-over board (Figure 12) is located on

the control box, behind the generator control panel. This

board has been provided for ease of voltage selection.

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

Maximum Amps

Table 8 shows the maximum amps the generator can

provide. DO NOT exceed the maximum amps as listed.

Table 8. Generator Maximum Amps

Model 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

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 25

GENERATOR OUTPUTS/GAUGE READING

HOW TO READ THE AC AMMETER AND AC

VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled

by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and

DO NOT effect the generator output. They are provided to

help observe how much power is being supplied, produced

at the UVWO terminals lugs.

Before taking a reading from either gauge, configure the

Voltage Change-Over Board (Figure 13) which produces

the desired output voltage.

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)

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 16)

in the U position and observe the current reading (load

drain) on the U terminal as indicated on the AC Ammeter

Gauge (Figure 17). This process can be repeated for

terminals V and W.

Figure 16. AC Ammeter

Change-Over Switch

Figure 17. AC Ammeter

(Amp reading on U Lug)

NOTICE

The ammeter gauge will only show a reading when

the Output Terminal Lugs are connected to a load

and in use.

PAGE 26 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

OUTPUT TERMINAL PANEL CONNECTIONS

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO

output terminal lugs. The voltages at the terminals are

dependent on the placement of the jumpers plates (6) on

the Voltage Change-Over Board and the adjustment of

the Voltage Regulator Control Knob.

Remember the voltage change-over board determines the

range of the output voltage and can be configured in two

different positions that provide 6 different output voltages

at the UVWO output terminals. The generator is shipped

from the factory in the 240V configuration. The voltage

regulator (VR) allows the user to increase or decrease the

selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V

operation as shown in Figure 18

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

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.

Figure 21. UVWO Terminal Lugs 1Ø-240V

Connections

1Ø-120V UVWO Terminal Output Voltages

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

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 27

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-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.

Figure 23. Voltage Change-Over Board 480V

Configuration

2. Connect the load wires to the UVWO terminals as

shown in Figure 24.

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.

1Ø-480V 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 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 26. UVWO Terminal Lugs 1Ø-277V

Connections

PAGE 28 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

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.

Table 9. Recommended Motor Oil

FUEL CHECK

Refilling the Fuel System

This generator has an internal fuel tank located inside

the trailer frame and may also be equipped with an

environmental fuel tank (Figure 28). ALWAYS fill the fuel

tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel

tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing

fuel. The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not

have a spout, use a funnel. Wipe up any spilled fuel

immediately.

Figure 28. Internal Fuel Tank System

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.

CAUTION

ONLY properly trained personnel who have read

and understand this section should refill the fuel tank

system.

Generator Internal Fuel Tank

Trailer Fuel Tank

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 29

INSPECTION/SETUP

Refueling Procedure:

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).

Figure 29. Only Fill on Level Ground

WARNING

Diesel fuel and its vapors are dangerous

to your health and the surrounding

environment. Avoid skin contact and/or

inhaling fumes.

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.

Level Ground

Unlevel Ground

=

Level Ground

Unlevel Ground

DO NOT fill on

unlevel ground

!

!

300

NOTICE

ONLY use #2 diesel fuel when refueling.

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

(from generator control panel position). Remove fuel

cap and fill tank (Figure 30).

Figure 30. Fueling the Generator

5. NEVER overfill fuel tank — It is important to read the

fuel gauge when filling trailer fuel tank. DO NOT wait

for fuel to rise in filler neck (Figure 31).

Figure 31. Full Fuel Tank

Figure 32. Fuel Expansion

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 32).

PAGE 30 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

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.

Operation in Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 11) has been added.

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.

Table 10. Coolant Capacity

Engine and Radiator 11.4 gal (43 liters)

Reserve Tank N/A

Table 11. Anti-Freeze

Operating Temperatures

Vol %

Anti-Freeze

Freezing Point

°C °F

50 -37 -34

NOTICE

When the antifreeze is mixed with water, the antifreeze

mixing ratio must be less than 50%.

Cleaning the Radiator

The engine may overheat if the radiator fins become

overloaded with dust or debris. Periodically clean the

radiator fins with compressed air. Cleaning inside the

machine is dangerous, so clean only with the engine turned

off and the negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect air

cleaner in accordance with the Cummins Engine Owner’s

Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect the fan belt for

damage and wear and adjust it in accordance with the

Cummins Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15

mm (Figure 33) when depressed with the thumb as shown

below.

Figure 33. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

INSPECTION/SETUP

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 31

BATTERY

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fluid level between the specified

marks. Battery life will be shortened, if the fluid level are

not properly maintained. Add only distilled water when

replenishment is necessary.

DO NOT over fill. Check to see whether the battery

cables are loose. Poor contact may result in poor starting

or malfunctions. Always keep the terminals firmly

tightened. Coating the terminals with an approved battery

terminal treatment compound. Replace battery with only

recommended type battery. The battery type used in this

generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity

of the battery fluid is 1.28 (at 68° F). If the specific gravity

should fall to 1.245 or lower, it indicates that the battery is

dead and needs to be recharged or replaced.

Before charging the battery with an external electric source,

be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 34) are properly

connected to the battery terminals as shown below. The

red cable is connected to the positive terminal of the

battery, and the black cable is connected to the negative

terminal of the battery.

Figure 34. Battery Connections

CAUTION

ALWAYS disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the Auto-Off/Reset-Manual Switch

is in either the AUTO or MANUAL position. ALWAYS

make sure that this switch is in the OFF/RESET

position when connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will

ensure a good connection and will help prevent

corrosion around the battery terminals.

ALTERNATOR

The polarity of the alternator is negative grounding type.

When an inverted circuit connection takes place, the

circuit will be in short circuit instantaneously resulting the

alternator failure.

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrosion and damage the

alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for

wear and tightness. Tighten all hose clamps and check

hoses for leaks.

If any hose (fuel or oil) lines are defective replace them

immediately.

CAUTION

Inadequate battery connections may cause poor

starting of the generator, and create other malfunctions.

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.

INSPECTION/SETUP

PAGE 32 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

GENERATOR START-UP PROCEDURE (MANUAL)

BEFORE STARTING

1. Place the main, G.F.C.I., and aux. circuit breakers

(Figure 35) in the OFF position prior to starting the

engine.

Figure 35. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been

configured for the desired output voltage.

3. Connect the load to the receptacles or the output

terminal lugs as shown in Figure 10. These load

connection points can be found on the output terminal

panel and the output terminal panel’s hard wire hookup

panel.

4. Tighten terminal nuts securely to prevent load wires

from slipping out.

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

Figure 36. Engine Enclosure Doors

CAUTION

The engine’s exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating.

Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI

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

INCORRECT

CORRECT

STARTING (MANUAL)

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

(down) position.

Figure 37. Engine Speed Switch (Low)

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

MANUAL position to start the engine (Figure 38).

Figure 38. Auto-Off/Reset Manua;Switch

(Manual Position)

3. Once the engine starts, let the engine run for 1-2

minutes (let engine idle longer in cold weather

conditions). Listen for any abnormal noises. If any

abnormalities exist, shut down the engine and correct

the problem. If the engine is running smoothly, place

the engine speed switch (Figure 39) in the HIGH (up)

position.

Figure 39. Engine Speed Switch (High)

4. The generator’s frequency meter (Figure 40) should be

displaying the 60 cycle output frequency in HERTZ.

Figure 40. Frequency Meter

NOTICE

If engine fails to start in a specified number attempts,

the shutdown lamp will illuminate and the Auto-Off/

Reset Switch must be place inthe Off/Reset position

before the engine can be restarted.

NOTICE

Engine will pre-heat automatically in cold weather

conditions." Glow Plug Hold " message will be displayed

and the engine will start automatically after pre-heating..

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 33

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,

Figure 41. Voltmeter

6. Use the voltage adjustment control knob (Figure 42)

to increase or decrease the desired voltage.

Figure 42. Voltage Adjust Control Knob

7. The ammeter (Figure 43) will indicate zero amps with

no load applied. When a load is applied, the ammeter

will indicate the amount of current that the load is

drawing from the generator.

Figure 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).

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).

PSI

OIL PRESS

0

25 50 75

100

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.

Figure 46. Engine Tachometer Gauge

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

ON position (Figure 47).

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.

Figure 48. Ammeter (Load)

13. The generator will run until manually stopped or an

abnormal condition occurs.

°F

WATER TEMP

100

140 180 220

260

RPMX10

SPEED

0

120 150 180

210

60

PAGE 34 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

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 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.

NOTICE

When the Auto Off/Reset Manual switch is placed

in the AUTO position, the engine glow plugs will be

warmed and the engine will start automatically.

When starting generator in AUTO mode use the “Manual

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

1. Perform steps 1 through 5 in the Before Starting section

as outlined in the Manual Starting Procedure.

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.

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).

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 35

GENERATOR SHUT-DOWN PROCEDURES

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.

Figure 51. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Place the Engine Speed Switch (Figure 52) in the

“LOW” (down) position.

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).

WARNING

NEVER stop the engine suddenly except in an

emergency.

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

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.

PAGE 36 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

*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.

Table 12. Inspection/Maintenance 10 Hrs

DAILY 250 Hrs 500 Hrs 1000

Hrs

Engine

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

Replace Engine Oil and Filter * 1X

Clean Air Filter X

Check Fuel Filter/Water Separator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*2X

Replace Air Filter Element * 3X

Check all Hoses and Clamps * 4X

Clean Inside of Fuel Tank X

Generator Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

MAINTENANCE

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..

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 37

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.

Figure 56. Fuel Tank Cleaning

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following

components should be inspected for wear:

Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber

suspension if necessary.

Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing 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.

PAGE 38 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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

“ON” position for 15-30 seconds. Try again, if needed. This

unit is equipped with an automatic air bleeding system.

CHECK OIL LEVEL

Check the crankcase oil level prior to each use, or when the

fuel tank is filled. Insufficient oil may cause severe damage

to the engine. Make sure the generator is level. The oil

level must be between the two notches on the dipstick as

shown in Figure 27.

Replacing Oil Filter

Remove the old oil filter.

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

Install the new oil filter.

After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for

leaks before adding more oil if needed. Clean excessive

oil from engine.

FLUSHING OUT RADIATOR AND REPLACING

COOLANT

Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open

the radiator cap while draining. Remove the overflow

tank and drain.

Check hoses for softening and kinks. Check clamps for

signs of leakage.

Tighten both cocks and replace the overflow tank.

Replace with coolant as recommended by the engine

manufacturer.

Close radiator cap tightly.

Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO

NOT clean radiator core with any objects, such as a

screwdriver.

WARNING

Allow engine to cool when flushing out

radiator. Flushing the radiator while hot

could cause serious burns from water or

steam.

RADIATOR CLEANING

The radiator (Figure 57) should be sprayed (cleaned) with

a high pressure washer when excessive amounts of dirt

and debris have accumulated on the cooling fins or tube.

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

(1.5 meters) away from the radiator to prevent damage to

the fins and tube.

Figure 57. Radiator Cleaning

GENERATOR STORAGE

For long term storage of the generator the following is

recommended:

Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

Completely drain the oil from the crankcase and refill if

necessary with fresh oil.

Clean the entire generator, internal and external.

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

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block

and completely remove the tires.

MAINTENANCE

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 39

MAINTENANCE

JACKET WATER HEATER AND INTERNAL BATTERY

CHARGER 120 VAC INPUT RECEPTACLES

(OPTIONAL)

This generator can be optionally equipped with two 120

VAC, 20 amp input receptacles located on the output

terminal panel.

The purpose of these receptacles is to provide power via

commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial

power has been supplied to them (Figure 58). To apply

commercial power to these receptacles, a power cord of

adequate size will be required (See Table 6).

When using the generator in hot climates there is no reason

to apply power to jacket water heater. However, if the

generator will be used in cold climates it is always a good

idea to apply power to the jacket water heater at all times.

To apply power to the jacket water heater simply apply

power to the jacket water heater receptacle via commercial

power using an power cord of adequate size.

Figure 58. Battery Charger and Jacket Water

Heater Power Connections

If the generator will be used daily, the battery should

normally not require charging. If the generator will be idle

(not used) for long periods of time, apply power to the

battery charger receptacle via commercial power using a

power cord of adequate size.

NOTICE

To ensure adequate starting capability, always have

power applied to the generator's internal battery

charger..

PAGE 40 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

Diesel Particulate Filter (DPF)

A diesel particulate filter (DPF) is a device designed to

remove diesel particulate matter (soot) from the exhaust

gas of a diesel engine. This type of filter usually removes

about 85-95% of the soot.

Soot accumulated in the DPF is removed via the

"regeneration process". Regeneration is the process

of removing the accumulated soot from the filter. This

regeneration process can occur in a few different ways.

Passive Regeneration — Occurs during normal

operation, typically under heavy load applications. Soot

is oxidized faster than it is collected.

Active Regeneration — Occurs when engine exhaust

temperatures are not high enough to oxidize the soot

collected in the DPF. Active regeneration requires

assistance from the engine to help increase the heat

level in the after-treatment system.

Active regeneration occurs at a normal engine speed

of 1800 rpm. In addition active regeneration is initiated

automatically by the Engine Control Module (ECM) timer

based program every 96 hours. This timer base program

will reset at the end of any regeneration mode.

Forced (Stationary) Regeneration — A forced

regeneration only occurs when the operator has initiated

this action at the ECU and the ECM recognizes a pre-

programmed set point of soot in the PDF to allow a forced

regeneration cycle.

This process can take anywhere from 30 minutes to

1-1/2 hours. When forced regeneration is in process all

loads must be removed from the generator, all circuit

breakers must be placed in the OFF position (OPEN),

and the engine speed set to idle.

DPF PRE-ALARM

In the event the Engine Control Unit (ECU) determines

the soot level back pressure and/or tempertaure has

reached a pre-determined trip point the ECU will indicate

a maintenance action is required by the operator.

This maintenance action will be shown on the LCD display

(DPF Warning Symbol) and the AMBER pre-alarm LED on

the ECU control panel will be ON (lit). See Figure 59.

Figure 59. ECU DPF Pre-Alarm

The DPF pre-alarm status symbol displayed in Figure 59

indicates the soot level buildup has exceeded a pre-

determined level and a "Forced Regeneration" action is

required.

Series 800 Controller

ECU

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Program

Exit

Option

DPF STAT

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 41

MAINTENANCE

Figure 60. ECU DPF Engine Shutdown

Series 800 Controller

ECU

Engine Started

Shutdown

Pre-Alarm

Alarm

Acknowledge

Screen

Change

Program

Exit

Option

DPF STAT

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).

FORCED REGENERATION PROCEDURE

Follow the steps below to initiate a forced regeneration:

1. Verify that the AMBER pre-alarm LED is ON or

FLASHING and the DPF symbol is shown on the

ECU display.

2. Place all circuit breakers in the OFF position.

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

4. Press the Program/Exit button on the ECU controller

and select FORCE REGEN mode.

5. Press and hold the request until the REGEN ACTIVE

message is displayed on the screen, then release.

6. Once activated, regeneration will start automatically

and the engine idling speed will increase through the

forced regeneration cycle. This process will last

anywhere from 30 minutes to 1-1/2 hours.

NOTICE

During the regeneration cycle the High

Exhaust System Temperature (HEST)

symbol may be displayed. Display of

this symbol can be considered normal

during the regeneration period.

ENGINE

EXHAUST (IN)

DIESEL OXIDATION

CATALYST (DOC)

DIESEL PARTICULATE

FILTER (DPF)

ENGINE

EXHAUST (OUT)

Figure 61. Typical DOC/DPF Unit

PAGE 42 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 43

TRAILER MAINTENANCE

BRAKES

Trailer brakes should be inspected the first 200 miles of

operation. This will allow the brake shoes and drums to seat

properly. After the first 200 mile interval, inspect the brakes

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

brakes more frequently.

Figure 62 displays the major hydraulic surge brake

components that will require inspection and maintenance.

Please inspect these components as required using steps

1 through 8 and Table 13 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

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.

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 62) should not require any

special attention with the exception of routine maintenance

such as shoe and lining replacement. Brake lines should

be periodically checked for cracks, kinks, or blockage.

Figure 62. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an

actuator at the tongue of the trailer. Remember the surge

or push of the trailer toward the tow vehicle automatically

synchronizes the trailer brakes with the tow vehicle brakes.

As the trailer pushes against the tow vehicle the actuator

telescopes together and applies force to the master

cylinder, supplying hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure

that it is functioning correctly. Never use an undersize actuator.

Table 13. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Weak Brakes or Brakes Pull to

One Side

Brake lining glazed? Reburnish or replace.

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.

Locking Brakes

Brake components loose, bent or

broken? Replace components.

Brake drums out-of-round? Replace.

Noisy Brakes

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Dragging Brakes

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.

PAGE 44 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

TRAILER MAINTENANCE

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing the

trailer wheels it is important the wheels, tires, and axle are

properly matched.

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.

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.

Table 14. Tire Wear Troubleshooting

Wear Pattern Cause Solution

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.

Flat Spots Wheel lockup and

tire skidding.

Avoid sudden stops when

possible and adjust brakes.

Suspension

The leaf suspension springs and associated components

(Figure 63) should be visually inspected every 6,000 miles

for signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 15.

Figure 63. Major Suspension Components

Table 15. Suspension Torque Requirements

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

Spring Eye Bolt

Snug fit only. Parts must rotate freely.

Locking nuts or cotter pins are

provided to retain nut-bolt assembly.

Shoulder Type

Shackle Bolt

Min-30 Max-50

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 45

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.

PAGE 46 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

TRAILER WIRING DIAGRAM

Figure 66. Trailer/Towing Vehicle Wiring Diagram

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 47

GENERATOR WIRING DIAGRAM

Figure 67. Generator Wiring Diagram

PAGE 48 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENGINE WIRING DIAGRAM

Figure 68. Engine Wiring Diagram

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 49

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our

company’s business office or service plant.

Table 17. Generator Troubleshooting

Symptom Possible Problem Solution

No Voltage Output

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

Low Voltage Output

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

High Voltage Output Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Circuit Breaker Tripped

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.

PAGE 50 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

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.

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

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 51

NOTES

PAGE 52 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

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

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

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

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

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

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the

same assembly or kit, which is indicated by a note in the

“Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate

multiple part numbers, which are in effect for the same

general item, such as different size saw blade guards in

use or a part that has been updated on newer versions

of the same machine.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a

part that has not been assigned a formal part number

at the time of publication.

A blank entry generally indicates that the item is not sold

separately or is not sold by Multiquip. Other entries will

be clarifi ed in the “Remarks” Column.

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.

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.

QTY. Column

Numbers Used

— Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other

parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold

separately. Other entries will be clarifi ed in the “Remarks”

Column.

REMARKS Column

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

Column are listed below. Other additional notes needed

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

same unique symbol will be included when this item is

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

— Used to list an effective serial

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”

“S/N XXXX AND ABOVE”

“S/N XXXX TO S/N XXX”

Specifi c Model Number Use

— Indicates that the part

is used only with the specifi c model number or model

number variant listed. It can also be used to show a

part is NOT used on a specifi c model or model number

variant.

Indicated by:

“XXXXX ONLY”

“NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can

be purchased at any hardware shop or made out of

available items. Examples include battery cables, shims,

and certain washers and nuts.

“Not Sold Separately”

— Indicates that an item cannot

be purchased as a separate item and is either part of an

assembly/kit that can be purchased, or is not available

for sale through Multiquip.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 53

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.

PAGE 54 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

GENERATOR ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 55

NO. PART NO. PART NAME QTY. REMARKS

1 C1110100302 ROTOR ASS'Y .........................................1 ............. INCLUDES ITEMS W/#

1-1# FIELD ASS'Y 1

1-2# 0601842334 RESISTOR 1

1-3# 0601823282 RECTIFIER 1

1-4# 0018205020 HEX. SOCKET HEAD CAP SCREW 2

1-4A# 0032005000 WASHER, LOCK 2

1-4B# 0401450050 WASHER, FLAT 2

1-5# 8171070002 FAN 1

1-6# 8171611003 COUPLING DISK 9

1-7# C1164200004 WASHER, COUPLING HUB 1

1-8# 8171015003 BALANCING PLATE .................................1 ............. WHEN PURCHASING BALANCING

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

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

1-9# 0012116045 HEX. HEAD BOLT 8

1-10# 0042616000 WASHER, LOCK 8

1-11# 0601000209 BALANCING WEIGHT KIT 1

1-12# C1112500004 BEARING FLANGE 1

1-13# 0071906314 BEARING 1

2 M3163400603 COUPING RING 1

3 Y0343204200 HEX. HEAD BOLT 8

4 EM923344 WASHER, LOCK 8

5 012112040 HEX. HEAD BOLT 8

6 0042512000 WASHER, LOCK 8

7 C1130000103 STATOR ASS'Y 1

7- 1 0226100420 RUBBER SEAL 1

7- 2 8171323004 CLAMPER 1

7- 3 0223300120 RUBBER SEAL 1

7- 4 8171323103 CLAMPER 1

7- 5 0221200300 RUBBER SEAL 1

7- 6 0010110035 HEX. HEAD BOLT 2

7- 7 031110160 WASHER, FLAT 2

7- 8 C1132200003 COVER 1

7- 9 0226000510 RUBBER SEAL 2

7- 10 0225000470 RUBBER SEAL 1

7- 11 0017106016 HEX. HEAD BOLT 6

7- 12 0601850144 GROMMET 1

8 C1154000002 END BRACKET 1

9 C1138000003 FIELD ASS'Y, EXCITER 1

10 0012110065 HEX. HEAD BOLT 4

10A 0042610000 WASHER, LOCK 4

10B 031110160 WASHER, FLAT 4

11 0017112045 HEX. HEAD BOLT 6

12 C1154400004 COVER, BEARING 1

13 C1154300004 GASKET, BEARING 1

14 0010106060 HEX. HEAD BOLT 4

14A 0040006000 WASHER, LOCK 4

14B 952404470 WASHER, FLAT 4

GENERATOR ASSY.

PAGE 56 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

GENERATOR ASSY. (CONTINUED)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 57

GENERATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

15 C1154400103 SUCTION COVER 1

16 011106015 HEX. HEAD BOLT 8

17 012112040 HEX. HEAD BOLT 12

18 0042512000 WASHER, LOCK 12

18-1 031112230 WASHER, FLAT 2

19 C1132300114 COVER, FAN 1

20 0010006030 HEX. HEAD BOLT 1

20A 952404470 WASHER, FLAT 1

20B 020106050 NUT 1

21 0605000012 RUBBER SUSPENSION 2

22 0030020000 HEX. NUT 4

22A 030220510 WASHER, LOCK 4

23 M3163600103 COUPL ING ADAPTER 1

24 012010030 HEX. HEAD BOLT 12

25 030210250 WASHER, LOCK 12

26 M3163700004 SPACER, BEARING 1

27 0070506207 BEARING 1

PAGE 58 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

CONTROL PANEL ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 59

NO. PART NO. PART NAME QTY. REMARKS

1 M4223000503 CONTROL PANEL 1

2 M9220100004 SET SCREW 2

2A Y0080200007 E-RING 2

3 M4223000604 CONTROL PANEL 1

4 0017108040 HEX. HEAD BOLT 4

5 0601840100 KNOB 1

6 0601801040 CHANGE-OVER SWITCH, AMMETER 1

7 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1

8 Y0602202642 ECU CONTROLLER 1

9 Y0602120569 GAUGE UNIT ASS'Y. 1

10 0601810171 PANEL LIGHT, 24V 1

11 0027104020 MACHINE SCREW 2

11A OEMAA8 HEX. NUT 2

12 0601831330 PANEL LIGHT SWITCH 1

13 0601831205 PUSH BUTTON 1

14 82608 TOGGLE SWITCH 1

15 0601830710 SWITCH, PANEL LIGHT 1

16 0601831557 EMERGENCY STOP BUTTON 1

17 0601807642 FEQUENCY METER, 45~65 HZ @240V 1

18 0601808992 AC AMMETER, 0~400A/800A:5A 1

19 0601800275 AC VOLTMETER, 0~600V 1

20 0601840073 VOLTAGE REGULATOR, 1K OHM 1

21 0605011211 PIN 1

22 M4246700604 WIRE HARNESS, GENERATOR 1

23 M4357200202 WIRE HARNESS, ENGINE 1

CONTROL PANEL ASSY.

PAGE 60 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

CONTROL BOX ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 61

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4213000212 CONTROL BOX 1

2 011008020 HEX. HEAD BOLT 14

3 M4213400104 BACK PANEL 1

4 M4213500104 TOP PANEL 1

5 011008020 HEX. HEAD BOLT 16

6 M4260500103 SET PANEL 1

7 011008020 HEX. HEAD BOLT 4

8 Y0602201456 MAGNETIC SWITCH 1

9 Y0602201457 MAGNETIC SWITCH 1

10 0016906016 HEX. HEAD BOLT 4

11 0601821370 RECTIFIER 2

12 0027104020 MACHINE SCREW 2

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

13A PTF08A RELAY BASE .....................................................1................REPLACES P/N 0601823109

13B PYCA1 RE LAY CLIP .....................................................1................REPLACES P/N 0601824400

14 0027104020 MACHINE SCREW 2

15 Y0601872130 HOLDER, FUSE 1

15A Y0601806603 FUSE,150A 1

16 0601815153 TERMINAL BLOCK 1

17 0027104020 MACHINE SCREW 2

18 0601802218 HOLDER, FUSE 1

18A 0601806671 FUSE (LEFT), 15A 1

18B 0601802131 FUSE (CENTER), 1A 1

18C 0601802133 FUSE (RIGHT), 5A 1

19 0027103020 MACHINE SCREW 2

20 0601809667 CURRENT TRANSFORMER 3

21 0027106020 MACHINE SCREW 6

22 Y0801820847 OVER CURRENT RELAY 1

23 0601820848 OVER CURRENT RELAY 1

24 0027104020 MACHINE SCREW 2

24A OEMAA8 HEX. NUT 2

25 Y0601807523 CIRCUIT BREAKER, 3P 600A 1

25-1 Y0601827412 REAR TERMINAL BUSBAR 2

26 014210040 HEX. HEAD BOLT 6

26A 021112140 SELF-LOCKING NUT 6

27 0601820604 AUTOMATIC VOLTAGE REGULATOR 1

PAGE 62 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

CONTROL BOX ASSY. (CONTINUED)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 63

NO. PART NO. PART NAME QTY. REMARKS

28 0027105016 MACHINE SCREW 4

29 M4273000003 TERM. BD, VOLTAGE CHANGE-OVER 1

30 011208030 HEX. HEAD BOLT 4

31 8181852104 CHANGE TERMINAL 10

32 Y0917106025 HEX. HEAD BOLT 20

33 8181853104 CHANGE-OVER PLATE 6

34 M4276200004 CHANGE PLATE 3

35 012210020 TIE BOLT 26

36 0041410000 WASHER, FLAT 26

37 0040010000 WASHER, LOCK 26

38 014210040 HEX. HEAD BOLT 3

38A 021112140 SELF-LOCKING NUT 3

39 Y0601808646 FUSE, 20A 1

40 M4213600104 STOPPER, CONTROL PANEL 1

41 952404470 WASHER, FLAT 1

42 505015300 SNAP PIN 1

43 0330000250 EDGING 1

44 0027104020 MACHINE SCREW 2

CONTROL BOX ASSY. (CONTINUED)

PAGE 64 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENGINE AND RADIATOR ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 65

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4923200054 ENGINE, CUMMINS QSB7-G6 1

1A Y0602015246 FAN BELT 1

1-1 Y0602046648 ELEMENT, AIR CLEANER, INNER 1

1-1A Y0602046649 ELEMENT, AIR CLEANER, OUTER 1

1-2 RBX002252 AIR CLEANER INDICATER 1

1-3 Y0602041296 CARTRIDGE, OIL FILTER 1

1-4 Y0602042578 CARTRIDGE, FUEL FILTER 1

2 M4303200603 ENGINE FOOT 1

3 M4303200703 ENGINE FOOT 1

4 0131151240 HEX. HEAD BOLT 6

4A 0040012000 WASHER, LOCK 6

5 M4357300103 HARNESS CLAMP 1

6 Y0191701800 BLOWBY HOSE 1

7 0605515149 HOSE BAND 2

8 Y0602022588 ADAPTER 1

9 Y0602022579 90° ELBOW 1

10 Y0379500800 DRAIN HOSE 1

11 Y0603306399 HOSE JOINT 1

12 Y0605511399 VALVE 1

13 Y0603306597 CONNECTOR 1

14 Y0603300286 LOCKNUT 1

15 Y0602021071 CAP 1

16 Y0602012739 RADIATOR/CAC ASS'Y 1

17 Y0602011024 CAP, RADIATOR 1

18 Y0343207038 HEX. HEAD BOLT 2

18A 0043007000 WASHER, LOCK 2

18B 0043107000 WASHER, FLAT 2

19 M4310201514 BRACKET 2

20 0343206120 HEX. HEAD BOLT 2

20A 030206150 WASHER, LOCK 2

20B 0043106000 WASHER, FLAT 2

21 0016310025 HEX. HEAD BOLT 4

22 Y0602013263 TUBE, CAC HOT SIDE 1

23 Y0602014823 TUBE, CAC COLD SIDE 1

24 Y0602015150 HOSE, HUMP 3

24A Y0605515258 CLAMP, HOSE 6

25 Y0602014822 TUBE, WATER INLET 1

26 Y0602015151 HOSE, 70-175, L=5- 00" 2

26A Y0605515257 CLAMP, HOSE 4

27 Y0602326067 U-BOLT SET 1

28 Y0602013262 TUBE, WATER OUTLET 1

29 Y0602015152 HOSE, 70-175 L=5. 00" 2

29A Y0605515256 CLAMP, HOSE 4

30 Y0602015153 HOSE, 70-100 L=52" 1

30A Y0605515259 CLAMP, HOSE 2

31 Y0605512198 HOSE JOINT 4

PAGE 66 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENGINE AND RADIATOR ASSY. (CONTINUED)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 67

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

32 Y0602015154 HOSE, 70-038 1=18" 1

33 Y0602015155 HOSE, 70-038 L=29.5" 1

34 Y0602015156 HOSE, 70-038 L=43. 5" 1

35 0605515198 HOSE BAND 6

36 Y0603307520 45° ELBOW 1

37 Y0605511394 VALVE 1

38 Y0605512192 HOSE JOINT 1

39 0193600400 DRAIN HOSE 1

40 Y0199101900 OVER FLOW HOSE 1

41 0605515170 HOSE BAND 2

42 Y0602211320 COOLANT LEVEL SWITCH 1

43 Y0605000010 RUBBER SUSPENSION 2

43A 0030012000 HEX. NUT 2

43B 0040012000 WASHER, LOCK 2

44 M3483600104 CLAMP 1

PAGE 68 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

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.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 69

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C1231700003 TERMINAL BOARD 1

2 M9220100304 OUTPUT TERMINAL BOLT 8

3 0801830804 TIE BOLT 8

4 3461860504 TERMINAL PLATE 3

5 0039316000 HEX. NUT 16

6 0040016000 WASHER, LOCK 24

7 0401450160 WASHER, FLAT 32

8 0016908040 HEX. HEAD BOLT 5

9 M4236100403 TERMINAL COVER 1

10 0016906016 HEX. HEAD BOLT 4

11 0605010040 HINGE 2

12 0027103010 MACHINE SCREW 4

12A 0207003000 HEX. NUT 4

12B 0041203000 WASHER, FLAT 4

13 0027103015 MACHINE SCREW 4

13A 0207003000 HEX. NUT 4

14 M4236100504 OUTPUT WINDOW 1

15 M9220100804 SET SCREW 2

16 0040006000 WASHER, LOCK 2

17 952404470 WASHER, FLAT 2

18 0080200005 RING 2

19 M4236100703 TERMINAL COVER 1

20 0805009804 STAY RUBBER 2

21 012212045 HEX. HEAD BOLT 2

22 031112230 WASHER, FLAT 4

23 0030012000 HEX. NUT 2

24 0605011505 STAY 1

25 0027105016 MACHINE SCREW 4

26 M4236400204 COVER 1

27 0016906016 HEX. HEAD BOLT 8

28 M4260600104 BRACKET, CIRCUIT BREAKER 1

28-1 0222100150 RUBBER CUSHION 1

29 011206020 HEX. HEAD BOLT 2

30 0601808803 CIRCUIT BREAKER, 1P, 20A 2

31 0601808804 CIRCUIT BREAKER, 2P, 50A 3

32 Y0601814014 RECEPTACLE, CS-6369L, 50A 3

33 0601814013 RECEPTACLE, GF-20LA, 20A 2

34 7538070 MACHINE SCREW 10

34A OEMAA8 HEX. NUT 10

35 0601850275 GROMMET I

36 0601815194 TERMINAL BLOCK 1

37 7538070 MACHINE SCREW 2

38 0603306775 BLIND PLUG 2

39 7538070 MACHINE SCREW 4

40 0017110025 HEX. HEAD BOLT 1

40A 0040510000 TOOTHED WASHER 1

41 M4236100604 INSULATING COVER 1

42 M4236400304 BRACKET 1

43 0016906016 HEX. HEAD BOLT 2

44 M4236400004 CABLE OUTLET COVER 1

45 M4236400104 SUPPORTER, CABLE OUTLET COVER 1

46 011206020 HEX. HEAD BOLT 8

PAGE 70 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

BATTERY ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 71

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220199 BATTERY 2

2 M9103000804 BATTERY BAND 1

3 0602220920 BATTERY BOLT SET .........................................2 ...............INCLUDES ITEMS W/#

3A# WING NUT 2

3B# PLASTIC WASHER 2

4 M9310500014 BATTERY SHEET 2

5 M4346900404 BATTERY CABLE 1

6 M3346902104 BATTERY CABLE 1

7 M4346900504 BATTERY CABLE 1

8 020108060 HEX. NUT 1

9 0040508000 TOOTHED WASHER 1

10 0016910025 HEX. HEAD BOLT 1

11 0040510000 TOOTHED WASHER 1

12 EARTH CABLE ..................................................1................MAKE LOCALLY

PAGE 72 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

MUFFLER ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 73

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 Y0602300240 DEVICE, AFTER TREATMENT 1

2 M4330400003 BRACKET 1

3 0016910025 HEX. HEAD BOLT 4

4 M2330400704 BAND 2

5 011008020 HEX. HEAD BOLT 2

6 0207308000 SUPER LOCK NUT 2

7 M4333000503 EXHAUST PIPE 1

8 Y0602325039 V-BAND CLAMP 1

8A Y0602320129 GASKET 1

9 Y0602325038 V-BAND CLAMP 1

9A Y0602320128 GASKET 1

10 M3330400804 EXHAUST PIPE COVER 1

11 M3330400903 EXHAUST PIPE BRACKET 1

12 011008020 HEX. HEAD BOLT 4

13 0602326062 U-BOLT SET 1

14 M4333100004 EXHAUST TAIL PIPE 1

15 M4357300014 HARNESS CLAMP 1

16 011008020 HEX. HEAD BOLT 2

17 0601851736 GROMMET 1

18 Y0602311130 EXHAUST INSULATING WRAP 1

19 0605515225 HOSE BAND 4

20 0602220911 CLAMP 1

21 0016910025 HEX. HEAD BOLT 1

PAGE 74 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

FUEL TANK ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 75

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4363000202 FUEL TANK 1

1-1 0605505070 FUEL TANK CAP 1

2 M4363200004 TANK BAND 2

3 M9310500104 SUPPORTER SHEET 4

4 011008020 HEX. HEAD BOLT 2

5 0207308000 SUPER LOCK NUT 2

6 0191302300 SUCTION HOSE 1

7 Y0191204000 RETURN HOSE 1

8 0605515109 HOSE BAND 4

9 Y0602042579 CART., FUEL WATER SEPARATOR 1

10 014210040 HEX. HEAD BOLT 2

11 Y0602022578 90° ELBOW 1

12 Y0602022985 HOSE JOINT 1

13 0602220911 CLAMP 1

13A 0016906016 HEX. HEAD BOLT 1

14 M1363400104 DRAIN HOSE 1

15 0605515198 HOSE BAND 2

16 1502025103C DRAIN JOINT 1

17 011206020 HEX. HEAD BOLT 2

18 0802011104 DRAIN BOLT 1

18A 0150000018 O-RING 1

PAGE 76 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENCLOSURE ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 77

ENCLOSURE 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.

NO. PART NO. PART NAME QTY. REMARKS

1 M4413000412 BASE 1

2 M1413400004 COVER 1

3 011008020 HEX. HEAD BOLT 2

4 M4423000512 FRONT FRAME I

4A M4493104603 ACOUSTIC SHEET 1

5 M4423000602 FRONT FRAME 1

5A M4493104603 ACOUSTIC SHEET 1

6 011008020 HEX. HEAD BOLT 10

7 0016910025 HEX. HEAD BOLT 10

8 M4423200004 COVER, FRONT FRAME 1

8A M4493100004 ACOUSTIC SHEET 1

9 0019208020 HEX. HEAD BOLT 22

10 M4423200503 TOP COVER, FRONT FRAME 1

11 0019208020 HEX. HEAD BOLT 15

12 M4433000212 CENTER FRAME 1

13 0010114040 HEX. HEAD BOLT 4

13A 030214350 WASHER, LOCK 4

13B 031114260 WASHER, FLAT 8

13C 515455840 HEX. NUT 4

14 0010120050 HEX. HEAD BOLT 4

14A 030220510 WASHER, LOCK 4

14B 0041220000 WASHER, FLAT 8

14C 0030020000 HEX. NUT 4

15 M4443000202 REAR FRAME 1

15A M4493302804 ACOUSTIC SHEET 1

16 0016910025 HEX. HEAD BOLT 4

17 M4443300404 COVER, REAR FRAME 1

17A M4493302904 ACOUSTIC SHEET 1

18 0019208020 HEX. HEAD BOLT 14

19 M4443300503 DUCT, REAR FRAME 1

19A M4493303004 ACOUSTIC SHEET 1

20 020108060 HEX. NUT 9

21 M4443200403 DOOR, REAR FRAME 1

22 M9110100204 HINGE 2

22A M9116100004 WASHER 2

23 0845031504 BLIND PLUG 2

PAGE 78 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENCLOSURE ASSY. (CONT.)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 79

ENCLOSURE ASSY. (CONT.)

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.

NO. PART NO. PART NAME QTY. REMARKS

24 0019208020 HEX. HEAD BOLT 3

25 0601850097 STOPPER 1

26 0027208025 MACHINE SCREW 1

27 M4443600004 WINDOW PLATE 1

28 020106050 SELF-LOCKING J NUT 8

28A 952404470 WASHER, FLAT 8

29 0600800320 MANUAL PACK 1

30 0021806016 MACHINE SCREW 4

31 M9114000002 DOOR HANDLE 1

32 0021806016 MACHINE SCREW 4

32A 020106050 HEX. NUT 4

33 M4463100302 ROOF PANEL 1

33A M4493503004 ACOUSTIC SHEET 1

34 0019208020 HEX. HEAD BOLT 10

35 M3310600004 COVER 1

36 0019208020 HEX. HEAD BOLT 4

37 M4463200502 ROOF PANEL 1

37A M4493503103 ACOUSTIC SHEET 1

38 0019208020 HEX. HEAD BOLT 16

39 0017110025 HEX. HEAD BOLT 4

40 M4463200304 COVER 2

41 Y0016908016 HEX. HEAD BOLT 12

42 M4463200603 DUCT, REAR ROOF 1

42A M4493503204 ACOUSTIC SHEET 1

43 0016908020 HEX. HEAD BOLT 10

44 M4463500204 GUTTER 2

45 0019206015 HEX. HEAD BOLT 8

46 M4453200202 SPLASHER PANEL 1

46A M4493403604 ACOUSTIC SHEET 1

47 0019108065 HEX. HEAD BOLT 6

47A 0042308000 WASHER, LOCK 6

47B 031108160 WASHER, FLAT 6

48 M4453001403 SIDE DOOR 1

48A M4493407404 ACOUSTIC SHEET 1

49 M4453001503 SIDE DOOR 1

49A M4493407504 ACOUSTIC SHEET 1

PAGE 80 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

ENCLOSURE ASSY. (CONT.)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 81

ENCLOSURE ASSY. (CONT.)

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.

NO. PART NO. PART NAME QTY. REMARKS

50 M4453001603 SIDE DOOR 1

50A M4493407604 ACOUSTIC SHEET 1

51 M4453001703 SIDE DOOR 1

51A M4493407704 ACOUSTIC SHEET 1

52 M4453301104 DUCT 3

52A M4493407804 ACOUSTIC SHEET 3

53 M4453301204 DUCT 1

53A M4493407904 ACOUSTIC SHEET 1

54 M4453301304 DUCT 1

54A M4493408004 ACOUSTIC SHEET 1

55 M4453301404 DUCT 1

55A M4493408104 ACOUSTIC SHEET 1

56 020108060 HEX. NUT 36

57 M9114000002 DOOR HANDLE 4

58 M9113000102 DOOR HANDLE 3

59 0021806018 MACHINE SCREW 28

59A 020106050 HEX. NUT 28

60 M4453600004 GUTTER 3

61 M4453600104 GUTTER 3

62 0019206015 HEX. HEAD BOLT 18

63 0845046904 HINGE 5

63A M9116100004 WASHER 5

64 0845047004 HINGE 6

64A M9116100004 WASHER . 6

65 0019208020 HEX. HEAD BOLT 25

66 0601850097 STOPPER 8

67 0027208025 MACHINE. SCREW 8

68 0845031504 BLIND PLUG 11

PAGE 82 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

RUBBER SEALS ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 83

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229201300 SEAL RUBBER 4

2 0229201200 SEAL RUBBER 1

3 0228901120 SEAL RUBBER 1

4 0228901260 SEAL RUBBER 3

5 0228900660 SEAL RUBBER 1

6 0228900795 SEAL RUBBER 4

7 0228901055 SEAL RUBBER 4

8 0228901200 SEAL RUBBER 3

9 0228900600 SEAL RUBBER 1

10 0229400630 SEAL RUBBER 1

11 0228801050 SEAL RUBBER 2

12 0228800590 SEAL RUBBER 1

13 0228100560 SEAL RUBBER 2

14 0228100370 SEAL RUBBER 2

15 0222100120 RUBBER SHEET 2

16 0222100180 RUBBER SHEET 2

PAGE 84 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

NAMEPLATE AND DECALS ASSY.

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 85

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

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

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

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

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

CONTROL PANEL AND BOX GROUP ...............................

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

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

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

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

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

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

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

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

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

ENGINE AND RADIATOR GROUP ...................

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

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

3-3 M9503000004 DECAL: WARNING, ROTATING PART .............2 ................M90300000

3-4 M9503000103 DECAL: WATER OIL CHECK ...........................1 ................M90300010

3-5 M9503100004 DECAL: WARNING, HOT COOLANT ...............1 ................M90310000

3-6 M9510100004 DECAL: CAUTION, HOT PARTS ....................1 ................M91010000

MOUNT TERMINAL GROUP ............................

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

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

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

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

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

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

BATTERY GROUP ............................................

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

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

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

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

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

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

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

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

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

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

PAGE 86 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

NAMEPLATE AND DECALS ASSY. (CONT.)

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 87

NAMEPLATE AND DECALS ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

ENCLOSURE GROUP

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

8-2 0600500090 EMBLEM 2

8-2A 0021106016 MACHINE SCREW 4

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

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

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

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

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

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

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

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

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

PAGE 88 — DCA220SSCU/4i 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (10/25/12)

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

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

Multiquip’s responsibility ceases when a

signed manifest has been obtained from the

carrier, and any claim for shortage or damage

must be settled between the consignee and

the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and

credit will be allowed, subject to the following

provisions:

A Returned Material Authorization 1.

must be approved by Multiquip prior to

shipment.

To obtain a Return Material Authorization, 2.

a list must be provided to Multiquip

Parts Sales that defines item numbers,

quantities, and descriptions of the items

to be returned.

The parts numbers and descriptions a.

must match the current parts price

list.

The list must be typed or computer b.

generated.

The list must state the reason(s) c.

for the return.

The list must reference the sales d.

order (s) or invoice (s) under

which the items were originally

purchased.

The list must include the name e.

and phone number of the person

requesting the RMA.

A copy of the Return Material Authorization 3.

must accompany the return shipment.

Freight is at the sender’s expense. All 4.

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

Parts must be in new and resalable 5.

condition, in the original Multiquip

package (if any), and with Multiquip part

numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a.

price book and shows as being

replaced by another item, it is

obsolete.)

Any parts with a limited shelf life b.

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

Any line item with an extended c.

dealer net price of less than

$5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper products.g.

Items purchased in kits.h.

The sender will be notified of any material 7.

received that is not acceptable.

Such material will be held for five 8.

working days from notification, pending

instructions. If a reply is not received

within five days, the material will be

returned to the sender at his expense.

Credit on returned parts will be issued 9.

at dealer net price at time of the original

purchase, less a 15% restocking

charge.

In cases where an item is accepted, for 10.

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

Credit issued will be applied to future 11.

purchases only.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a

specific date and all orders received on or

after that date will be billed at the revised price.

Rebates for price declines and added charges

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and

sell direct to Government agencies, and to

Original Equipment Manufacturer accounts

who use our products as integral parts of their

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the

invoice for special handling including bus

shipments, insured parcel post or in cases

where Multiquip must personally deliver the

parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder for

damages in excess of the purchase price of

the item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of profit or good will or for any

other special, consequential or incidental

damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are

made in connection with the sale of parts or

trade accessories nor as to any engine not

manufactured by Multiquip. Such warranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes nor

authorizes any person to assume for it

any other obligation or liability whatever in

connection with the sale of its products. Apart

from such written statement of warranty,

there are no warranties, express, implied or

statutory, which extend beyond the description

of the products on the face hereof.

Effective: February 22, 2006

DCA220SSCU/4i 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (10/25/12) — PAGE 89

NOTES

OPERATION MANUAL

Your Local Dealer is:

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Office MQ Parts Department

18910 Wilmington Ave.

Carson, CA 90746

Contact: mq@multiquip.com

Tel. (800) 421-1244

Fax (310) 537-3927

800-427-1244

310-537-3700

Fax: 800-672-7877

Fax: 310-637-3284

Service Department Warranty Department

800-421-1244

310-537-3700

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.