Page 2 - prOpOsitiON 65 WarNiNG; Diesel engine exhaust and some of
page 2 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) prOpOsitiON 65 WarNiNG Diesel engine exhaust and some of
Page 3 - You can also obtain information about motor vehicle safety from; repOrtiNG safety DefeCts
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 Multi...
Page 4 - taBLe Of CONteNts; Component Drawings; NOTICE
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 ......................
Page 5 - NOtes
dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 5 NOtes
Page 6 - safety iNfOrMatiON; saFeTY messages; danger
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 s...
Page 7 - general saFeTY; generaTor saFeTY
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 r...
Page 8 - engine saFeTY
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 requi...
Page 9 - Fuel saFeTY; ToWing saFeTY; Safety Towing Regulations,
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-vent...
Page 10 - elecTrical saFeTY; power cord/cable safety; grounding safety
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 electr ical ...
Page 11 - BaTTerY saFeTY; environmenTal saFeTY
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 combusti...
Page 12 - speCifiCatiONs; Table 1. generator specifications
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 sta...
Page 13 - DiMeNsiONs
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 B C 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 ...
Page 14 - iNstaLLatiON; Figure 2. Typical Generator Grounding Application
page 14 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) iNstaLLatiON Figure 2. Typical Generator Grounding Application
Page 15 - ouTdoor insTallaTion; do noT; generaTor grounding; earTh; alWaYs
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. A...
Page 16 - GeNeraL iNfOrMatiON
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 indust...
Page 17 - MajOr COMpONeNts; Figure 3. Major Components
dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 17 MajOr COMpONeNts 220 220 U V W O GND Denyo OFF W U V OFF W-U V-W U-V DECREASE INCREASE PSI OIL PRESS 0 25 50 75 100 °F WATER TEMP 100 140 180 220 260 VOLTS BATTERY 6 12 18 24 30 FUEL E ½ F RPMX10 SPEED 0 120 150 180 210 6...
Page 19 - eNGiNe/GeNeratOr CONtrOL paNeL; Figure 5. Gauge Unit Assembly
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....
Page 20 - OUtpUt terMiNaL paNeL faMiLiariZatiON; ouTpuT Terminal panel; ouTpuT Terminal FamiliarizaTion; Figure 6. Output Terminal Panel
page 20 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) OUtpUt terMiNaL paNeL faMiLiariZatiON 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...
Page 21 - 20 vac gFci receptacles; board; reset; Twist lock dual voltage 120/240 vac receptacles; only; Receptacles; output terminal lugs.; increase; Figure 9. Voltage Regulator Control Knob
dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 21 OUtpUt terMiNaL paNeL faMiLiariZatiON 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 cha...
Page 22 - connecting loads; Figure 10. Connecting Loads; over current relay; Figure 11. Over Current Relay
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 befo...
Page 23 - LOaD appLiCatiON; single phase load; Table 5. power Factor By load; Three phase load
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...
Page 24 - GeNeratOr OUtpUts; generaTor ouTpuT volTages; Table 7. voltages available; maximum amps; Table 8. generator maximum amps
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 boa...
Page 25 - GeNeratOr OUtpUts/GaUGe reaDiNG; hoW To read The ac ammeTer and ac; ac voltmeter gauge reading; Figure 17. AC Ammeter
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 lo...
Page 26 - OUtpUt terMiNaL paNeL CONNeCtiONs; uvWo Terminal ouTpuT volTages; voltage change-over Board; Ø-240v uvWo Terminal output voltages; Connections
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 j...
Page 27 - must; Figure 23. Voltage Change-Over Board 480V; Ø-480v uvWo Terminal output voltages; Ø-277v uvWo Terminal output voltages
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. R...
Page 28 - Figure 27. Engine Oil Dipstick; Table 9. recommended motor oil; Fuel checK; Figure 28. Internal Fuel Tank System; Generator Internal Fuel Tank
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-...
Page 29 - Figure 29. Only Fill on Level Ground; Figure 30. Fueling the Generator
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 Fil...
Page 30 - operation in Freezing Weather; Table 10. coolant capacity; cleaning the radiator; Figure 33. Fan Belt Tension
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. S...
Page 31 - Figure 34. Battery Connections; alTernaTor
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 ...
Page 32 - BeFore sTarTing; Figure 36. Engine Enclosure Doors
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 ...
Page 33 - Figure 45. Coolant Temperature Gauge
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 voltag...
Page 35 - GeNeratOr shUt-DOWN prOCeDUres; normal shuTdoWn procedure; Switch; emergencY shuTdoWn procedure; Figure 54. Emergency Stop Button
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. ...
Page 36 - dailY; MaiNteNaNCe; general inspecTion; engine side; air cleaner; red; “red”
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 indicato...
Page 37 - Figure 56. Fuel Tank Cleaning
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 consumpti...
Page 38 - Figure 57. Radiator Cleaning
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 crank...
Page 39 - JacKeT WaTer heaTer and inTernal BaTTerY; jacket water heater; Figure 58. Battery Charger and Jacket Water
dca220sscu/4i 60 hz generaTor• operaTion manual — rev. #0 (10/25/12) — page 39 MaiNteNaNCe JacKeT WaTer heaTer and inTernal BaTTerY c h a r g e r 1 2 0 vac i n p u T r e c e p Tac l e s (opTional) This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the out...
Page 40 - emission conTrol
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 cat...
Page 41 - Figure 60. ECU DPF Engine Shutdown; Forced regeneraTion procedure
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 (Fig...
Page 42 - traiLer MaiNteNaNCe; Trailer mainTenance
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 r...
Page 43 - BraKes; Figure 62. Hydraulic Brake Components; actuator; surge
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...
Page 44 - suspension; Figure 63. Major Suspension Components
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 ver y impor tant and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and a...
Page 45 - lug nut Torque requirements; do; Figure 64. Wheel Lug Nuts; never
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...
Page 46 - traiLer WiriNG DiaGraM; Figure 66. Trailer/Towing Vehicle Wiring Diagram
page 46 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) traiLer WiriNG DiaGraM Figure 66. Trailer/Towing Vehicle Wiring Diagram
Page 47 - GeNeratOr WiriNG DiaGraM; Figure 67. Generator 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 - eNGiNe WiriNG DiaGraM; Figure 68. Engine 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
Page 50 - trOUBLeshOOtiNG DiaGNOstiCs; Figure 69. Hour Check Button
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...
Page 52 - expLaNatiON Of CODe iN reMarks COLUMN; sample parTs lisT; remarKs column
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 ther...
Page 53 - sUGGesteD spare parts; dca220sscu/dca220sscu4i WhisperWaTT generaTor WiTh; description
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 .......
Page 57 - SUCTION COVER
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 C1...
Page 64 - eNGiNe aND raDiatOr assy.
page 64 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) eNGiNe aND raDiatOr assy.
Page 65 - parT name
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 ...
Page 68 - OUtpUt terMiNaL assy.
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 G...
Page 84 - NaMepLate aND DeCaLs assy.
page 84 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) NaMepLate aND DeCaLs assy.
Page 87 - EMBLEM
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-...
Page 88 - terMs aND CONDitiONs Of saLe — parts
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 shipm...
Page 90 - OperatiON MaNUaL; Your Local Dealer is:; HERE’S HOW TO GET HELP; PLEASE HAVE THE MODEL AND SERIAL; United StateS; Canada
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: [email protected] Tel. (800) 421-1244 Fax (310) 537-3927 800-427-1244...
