Multiquip Portable Generator DCA220SSCU User Manual

OperatiON aND parts MaNUaL  
®
WhisperWatt™ series  
MODeL DCa220ssCU  
MODeL DCa220ssCU4i  
60hz GeNeratOr  
(CUMMiNs QsB7-G6 DieseL eNGiNe)  
parts List NO. M4870300204  
Revision #0 (10/25/12)  
To find the latest revision of this  
publication, visit our website at:  
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
repOrtiNG safety DefeCts  
If you believe that your vehicle has a defect that could cause a crash or could cause  
injury or death, you should immediately inform the National Highway Traffic Safety  
Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.  
If NHTSA receives similar complaints, it may open an investigation, and if it finds  
that a safety defect exists in a group of vehicles, it may order a recall and remedy  
campaign. However, NHTSA cannot become involved in individual problems  
between you, your dealer, or Multiquip.  
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-  
Administrator  
NHTSA  
1200 New Jersey Avenue S.E.  
Washington, DC 20590  
You can also obtain information about motor vehicle safety from  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
taBLe Of CONteNts  
Component Drawings  
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  
Generator Assembly......................................... 54-57  
Control Panel Assembly ................................... 58-59  
Control Box Assembly ...................................... 60-63  
Engine And Radiator Assembly........................ 64-65  
Output Terminal Assembly................................ 66-67  
Battery Assembly.............................................. 68-69  
Muffler Assembly.............................................. 70-71  
Fuel Tank Assembly.......................................... 72-73  
Enclosure Assembly......................................... 74-79  
Rubber Seals Assembly ................................. 80-81  
Nameplate And Decals Assembly .................... 82-85  
Terms And Conditions Of Sale — Parts ................ 86  
NOTICE  
Specifications are subject to change without notice.  
page 4 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOtes  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
Do not operate or service the equipment before reading the  
entire manual. Safety precautions should be followed at all  
times when operating this equipment. Failure to read and  
understand the safety messages and operating instructions  
could result in injury to yourself and others.  
Potential hazards associated with the operation of this  
equipment will be referenced with hazard symbols which  
may appear throughout this manual in conjunction with  
safety messages.  
saFeTY messages  
The four safety messages shown below will inform you  
about potential hazards that could injure you or others.The  
safety messages specifically address the level of exposure  
to the operator and are preceded by one of four words:  
danger, Warning, cauTion or noTice.  
saFeTY sYmBols  
danger  
Indicates a hazardous situation which, if not avoided,  
Will result in deaTh or serious inJurY.  
Warning  
Indicates a hazardous situation which, if not avoided,  
could result in deaTh or serious inJurY.  
cauTion  
Indicates a hazardous situation which, if not avoided,  
could result in minor or moderaTe inJurY.  
NOTICE  
Addresses practices not related to personal injury.  
page 6 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
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.  
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.  
alWaYs know the location of the nearest  
fire extinguisher.  
alWaYs know the location of the nearest  
first aid kit.  
alWaYs know the location of the nearest  
phone or keep a phone on the job site. Also, know the  
phone numbers of the nearest ambulance, doctor and  
fire department. This information will be invaluable in  
the case of an emergency.  
never operate this equipment when not  
feeling well due to fatigue, illness or when  
under medication.  
never operate this equipment under the influence of  
drugs or alcohol.  
generaTor saFeTY  
danger  
neveroperatetheequipmentinanexplosive  
atmosphereornearcombustiblematerials.An  
explosion or fire could result causing severe  
bodily harm or even death.  
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.  
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.  
NOTICE  
This equipment should only be operated by trained and  
qualified personnel 18 years of age and older.  
Whenever necessary, replace nameplate, operation and  
safety decals when they become difficult read.  
cauTion  
Manufacturer does not assume responsibility for any  
accident due to equipment modifications. Unauthorized  
equipment modification will void all warranties.  
never lubricate components or attempt service on a  
running machine.  
NOTICE  
alWaYs ensure generator is on level ground before use.  
alWaYs keep the machine in proper running condition.  
Fix damage to machine and replace any broken parts  
immediately.  
alWaYs store equipment properly when it is not being  
used.Equipment should be stored in a clean, dry location  
out of the reach of children and unauthorized personnel  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
engine saFeTY  
NOTICE  
danger  
never run engine without an air filter or with a dirty air  
filter.Severe engine damage may occur.Service air filter  
frequently to prevent engine malfunction.  
The engine fuel exhaust gases contain poisonous carbon  
monoxide. This gas is colorless and odorless, and can  
cause death if inhaled.  
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.  
The engine of this equipment  
requires an adequate free  
flow of cooling air. never  
operate this equipment in  
any enclosed or narrow area  
where free flow of the air is  
restricted. If the air flow is  
restricted it will cause injury to people and property and  
serious damage to the equipment or engine.  
Wet stacking is a common problem with diesel engines  
which are operated for extended periods with light or  
no load applied.When a diesel engine operates without  
sufficient load (less than 40% of the rated output), it will  
not operate at its optimum temperature. This will allow  
unburned fuel to accumulate in the exhaust system,  
which can foul the fuel injectors, engine valves and  
exhaust system, including turbochargers, and reduce  
the operating performance.  
Warning  
do noT place hands or fingers inside engine  
compartment when engine is running.  
In order for a diesel engine to operate at peak efficiency,  
it must be able to provide fuel and air in the proper ratio  
and at a high enough engine temperature for the engine  
to completely burn all of the fuel.  
never operate the engine with heat shields or  
guards removed.  
Keep fingers, hands hair and clothing away  
from all moving parts to prevent injury.  
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.  
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.  
State Health Safety Codes and Public Resources  
Codes specify that in certain locations, spark arresters  
must be used on internal combustion engines that use  
hydrocarbon fuels.A spark arrester is a device designed  
to prevent accidental discharge of sparks or flames  
from the engine exhaust. Spark arresters are qualified  
and rated by the United States Forest Service for this  
purpose. In order to comply with local laws regarding  
spark arresters, consult the engine distributor or the  
local Health and Safety Administrator.  
do noT remove the engine oil drain plug while the  
engine is hot. Hot oil will gush out of the oil tank and  
severely scald any persons in the general area of the  
generator.  
cauTion  
never touch the hot exhaust manifold,  
muffler or cylinder.Allow these parts to cool  
before servicing equipment.  
page 8 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
Make sure the hitch and coupling of the towing vehicle  
are rated equal to, or greater than the trailer “gross  
vehicle weight rating.”  
Fuel saFeTY  
danger  
do noT start the engine near spilled fuel or combustible  
fluids. Diesel fuel is extremely flammable and its vapors  
can cause an explosion if ignited.  
alWaYs inspect the hitch and coupling for wear. never  
tow a trailer with defective hitches, couplings, chains, etc.  
Check the tire air pressure on both towing vehicle and  
trailer. Trailer tires should be inflated to 50 psi cold.  
Also check the tire tread wear on both vehicles.  
alWaYs refuel in a well-ventilated area, away from  
sparks and open flames.  
alWaYs use extreme caution when working with  
flammable liquids.  
alWaYs make sure the trailer is equipped with a safety  
chain.  
do noT fill the fuel tank while the engine is running  
or hot.  
alWaYs properly attach trailer’s safety chains to towing  
vehicle.  
do noT overfill tank, since spilled fuel could ignite if it  
comes into contact with hot engine parts or sparks from  
the ignition system.  
alWaYs make sure the vehicle and trailer directional,  
backup, brake and trailer lights are connected and  
working properly.  
Store fuel in appropriate containers, in well-ventilated  
areas and away from sparks and flames.  
DOT Requirements include the following:  
• Connect and test electric brake operation.  
never use fuel as a cleaning agent.  
• Secure portable power cables in cable tray with tie  
wraps.  
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.  
The maximum speed for highway towing is55 mphunless  
posted otherwise.Recommended off-road towing is not to  
exceed 15 mph or less depending on type of terrain.  
ToWing saFeTY  
Avoid sudden stops and starts.This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve towing.  
cauTion  
Check with your local county or state safety  
towing regulations, in addition to meeting  
Department of Transportation (DOT)  
SafetyTowing Regulations, before towing  
your generator.  
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.  
Refer to MQ Power trailer manual for additional safety  
information.  
Place chock blocks underneath wheel to prevent rolling  
while parked.  
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.  
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.  
alWaYs shutdown engine before transporting  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
Make sure power cables are securely connected to the  
generator’s output receptacles. Incorrect connections  
may cause electrical shock and damage to the  
generator.  
elecTrical saFeTY  
danger  
do noT touch output terminals during  
operation. Contact with output terminals  
duringoperationcancauseelectrocution,  
electrical shock or burn.  
NOTICE  
alWaYs make certain that proper power or extension  
cord has been selected for the job. See Cable Selection  
Chart in this manual.  
The electrical voltage required to  
operate the generator can cause severe  
grounding safety  
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.  
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 insert any objects into the output  
receptacles during operation. This is  
extremely dangerous.The possibility exists  
of electrical shock, electrocution or  
death.  
never use gas piping as an electrical ground.  
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.  
page 10 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety iNfOrMatiON  
BaTTerY saFeTY  
environmenTal saFeTY  
danger  
NOTICE  
do noT drop the battery. There is a possibility that the  
battery will explode.  
Dispose of hazardous waste properly.  
Examples of potentially hazardous waste  
are used motor oil, fuel and fuel filters.  
do noT expose the battery to open flames,  
sparks, cigarettes, etc.The battery contains  
combustible gases and liquids. If these  
gases and liquids come into contact with a  
flame or spark, an explosion could occur.  
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.  
Warning  
alWaYswearsafetyglasseswhenhandling  
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  
environmenttoavoidtheriskofadangerousconcentration  
of combustible gasses.  
If the battery liquid (dilute sulfuric acid) comes into  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
If the battery liquid (dilute sulfuric acid) comes into  
contact with eyes, rinse eyes immediately with plenty  
of water and contact the nearest doctor or hospital to  
seek medical attention.  
cauTion  
alWaYs disconnect the negaTive battery terminal  
before performing service on the generator.  
alWaYs keep battery cables in good working condition.  
Repair or replace all worn cables.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
speCifiCatiONs  
Table 1. generator specifications  
DCA220SSCU/ DCA220SSCU4i  
model  
Revolving field, self ventilated,  
open protected type synchronous generator  
Type  
armature connection  
phase  
star with neutral  
3
standby output  
prime output  
194 kW (242 kVA)  
176 kW (220 kVA)  
voltage (l-l/l-n)  
voltage change-over Bd. at 3Ø 240/139  
208Y/120, 220Y/127, 240Y/139  
416Y/240, 440Y/254, 480Y/277  
240/120  
voltage (l-l/l-n)  
voltage change-over Bd. at 3Ø 480/277  
voltage (l-l/l-n)  
voltage change-over Bd. at 1Ø 240/120  
power Factor  
Frequency  
0.8  
60 Hz  
speed  
1800 rpm  
aux. ac power  
aux. voltage/output  
dry Weight  
Single Phase, 60 Hz  
4.8 Kw (2.4 kW x 2)  
6,636 lbs. (3,010 kg)  
7,496 lbs. (3,400 kg)  
Wet Weight  
Table 2. engine specifications  
model  
Cummins QSB7-G6 EPA Interim Tier 4 Certified  
4 cycle, water-cooled, direct injection, turbo-charged  
air cooled and EGR  
Type  
no. of cylinders  
Bore x stroke  
displacement  
rated output  
6 cylinders  
4.21 in. x 4.88 in. (107 mm x 124 mm)  
409 cu. in. (6.7 liter)  
282 HP at 1800 rpm  
starting  
Electric  
11.4 gal. (43.0 liters)1  
4.6 gal. (17.5 liters)2  
coolant capacity  
lube oil capacity  
lubricatingType oil  
Fuel Type  
API service class CJ-4 SAE 15W-40  
#2 Diesel Fuel (Ultra low sulfur diesel fuel only)  
100 gal. (380 liters)  
Fuel Tank capacity  
12.4 gal. (46.8 L)/hr at full load 9.5 gal. (36.0 L)/hr at 3/4 load  
Fuel consumption  
6.9 gal. (26.0 L)/hr at 1/2 load  
4.4 gal. (16.8 L)/hr at 1/4 load  
Battery  
1 Includes engine and radiator hoses  
2 Includes filters  
27 (CCA 0°F 800A) X 2  
page 12 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
DiMeNsiONs  
C
B
MAXIMUM  
LIFTING  
POINT  
TOP VIEW  
14,050 lbs.  
(6,373 kg)  
D
A
E
220  
SIDE VIEW  
F
FRONT VIEW  
Figure 1. Dimensions  
Table 3. dimensions  
G
reference  
letter  
dimension in. (mm)  
reference letter  
dimension in. (mm)  
A
B
C
D
31.10 in. (790 mm)  
31.10 in. (790 mm)  
41.33 in. (1,050 mm)  
41.33 in. (1,050 mm)  
E
F
41.33 in. (1,050 mm.)  
137.79 in. (3,500 mm)  
68.89 in. (1,750 mm)  
51.18 in. (1,300 mm)  
G
H
H
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNstaLLatiON  
Figure 2. Typical Generator Grounding Application  
page 14 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNstaLLatiON  
ouTdoor insTallaTion  
generaTor grounding  
Install the generator in a area that is free of debris,  
bystanders, and overhead obstructions. Make sure the  
generator is on secure level ground so that it cannot slide  
or shift around. Also install the generator in a manner so  
that the exhaust will not be discharged in the direction of  
nearby homes.  
To guard against electrical shock and possible damage to  
the equipment, it is important to provide a good earTh  
ground (Figure 2).  
Article 250 (Grounding) of the National Electrical Code  
(NEC) provides guide lines for proper grounding and  
specifies that the cable ground shall be connected to the  
grounding system of the building as close to the point of  
cable entry as practical.  
The 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.  
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.  
Foreign materials such as dust, sand, lint and abrasive  
materials have a tendency to cause excessive wear to  
engine and alternator parts.  
a. Copper - 8 AWG (5.3 mm2)  
b. Aluminum - 6 AWG (8.4 mm2)  
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.  
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.  
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.  
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.  
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.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeraL iNfOrMatiON  
generaTor  
open delTa exciTaTion sYsTem  
This generator (Figure 3) is designed as a high quality  
portable (requires a trailer for transport) power source for  
telecom sites, lighting facilities, power tools, submersible  
pumps and other industrial and construction machinery.  
Each generator is equipped with the state of the art 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.  
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  
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.  
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)  
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 ceilingand responds  
according the demands of the required load.  
AC Ammeter (Amps)  
engine  
AC Voltmeter (Volts)  
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.  
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  
In keeping with MQ Power’s policy of constantly improving  
its products, the specifications quoted herein are subject  
to change without prior notice.  
• Over-Current Relay  
• Starter Relay  
elecTric governor sYsTem  
TheelectricgovernorsystemcontrolstheRPMsoftheengine.  
When the engine demand increases or decreases, the  
governor system regulates the frequency variation to .25%.  
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  
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.  
Battery Charger (Optional)  
Jacket Water Heater (Optional)  
page 16 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MajOr COMpONeNts  
1
2
220  
3
4
6
5
220  
U
V
W
O
GND  
7
10  
11  
Table 4. generator major components  
iTem no.  
descripTion  
Muffler Assembly  
1
2
50  
180  
°F  
18  
25  
75  
140  
12  
220  
24  
PSI  
VOLTS  
0
100  
100  
260  
6
30  
INCREASE  
DECREASE  
OIL PRESS  
WATER TEMP  
BATTERY  
½
150  
120  
180  
RPMX10  
210  
60  
E
F
0
V
FUEL  
SPEED  
Enclosure Assembly  
U
W
OFF  
V-W  
OFF  
ECU  
Series 800 Controller  
Engine Started  
U-V  
W-U  
8
Shutdown  
Pre-Alarm  
3
Generator Assembly  
Alarm  
Screen  
Program/  
Exit  
Option  
A
c
k
n
o
w
l
e
d
g
e
C
h
a
n
g
e
4
Battery Assembly  
5
Engine Assembly  
9
6
Fuel Tank Assembly  
7
Output Terminal Assembly  
Circuit Breaker Assembly  
Auto Start/Stop Controller Assembly  
Gauge Unit Assembly  
Operating Panel Assembly  
Denyo  
8
9
10  
11  
Figure 3. Major Components  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe CONtrOL UNit (eCU)  
1
ECU  
Series 800 Controller  
50  
180  
°F  
18  
25  
75  
140  
12  
220  
24  
PSI  
VOLTS  
0
100  
INCREASE  
DECREASE  
Engine Started  
100  
260  
6
30  
B
C
D
OIL PRESS  
WATER TEMP  
BATTERY  
½
150  
120  
180  
RPMX10  
210  
Shutdown  
Pre-Alarm  
60  
°F  
V
E
F
0
A
FUEL  
SPEED  
U
W
OFF  
V-W  
OFF  
ECU  
Series 800 Controller  
Engine Started  
U-V  
W-U  
Shutdown  
Pre-Alarm  
Alarm Screen  
Acknowledge Change  
Program  
Exit  
Option  
Alarm Screen  
Acknowledge Change  
Program  
Exit  
Option  
E
F G  
H
Figure 4. Engine Control Unit (ECU)  
The definitions below describe the controls and functions  
of the Engine Control Unit (Figure 4).  
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.  
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.  
F. screen change Button — When this button is  
pushed during operation, the screen will cycle  
through each parameter screen.  
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.  
G. option Button — This button is not active. Do  
not use.  
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  
H. program/exit Button — Pushing this button  
allows the DPF Force Regen and diagnostic code  
to be confirmed.  
page 18 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe/GeNeratOr CONtrOL paNeL  
1
3
2
4
7
50  
180  
°F  
18  
25  
75  
140  
12  
220  
24  
A
B
C
PSI  
VOLTS  
0
100  
50  
100  
260  
6
30  
180  
°F  
18  
INCREASE  
DECREASE  
25  
75  
140  
12  
220  
24  
OIL PRESS  
WATER TEMP  
BATTERY  
8
½
150  
PSI  
VOLTS  
120  
180  
60  
0
100  
100  
6
260  
30  
°F  
RPMX10  
E
F
0
210  
V
14  
FUEL  
SPEED  
U
W
OIL PRESS  
WATER TEMP  
BATTERY  
OFF  
9
5
V-W  
OFF  
D
½
E
150  
120  
ECU  
180  
Series 800 Controller  
U-V  
W-U  
60  
Engine Started  
°F  
RPMX10  
Shutdown  
Pre-Alarm  
E
0
F
210  
FUEL  
SPEED  
6
Alarm Screen  
Acknowledge Change  
Program  
Exit  
Option  
10  
11  
13  
12  
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.  
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).  
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.  
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.  
8. ammeter change-over switch — This switch allows  
theACammetertoindicatethecurrentowingtotheload  
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.  
B. Water Temperature gauge — During normal  
operation this gauge be should read between 180°  
and 225°F (82°~107°C).  
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.  
C. charging voltmeter gauge — During normal  
operation this gauge indicate minimum 26 VDC  
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.  
D. Fuel gauge — Indicates amount of diesel fuel  
available.  
11. engine speed switch — This switch controls the  
speed of the engine (low/high).  
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. .  
12. auto/start switch This switch selects either manual  
or automatic operation .Center position is OFF (reset).  
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.  
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.  
3. panel light switch — When activated will turn on  
control panel light.  
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.  
4. Frequency meter — Indicates the output frequency  
in hertz (Hz). Normally 60 Hz  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL paNeL faMiLiariZatiON  
ouTpuT Terminal panel  
ouTpuT Terminal FamiliarizaTion  
The Output Terminal Panel (Figure 7) shown below is  
located on the right-hand side (left from control panel) of  
the generator. Lift up on the cover to gain access to  
receptacles and terminal lugs.  
The “Output Terminal Panel ” (Figure 7) is provided with  
the following:  
Three (3) 240/139V output receptacles @ 50 amp  
Three (3) Circuit Breakers @ 50 amps  
NOTICE  
Two (2) 120V GFCI receptacles @ 20 amp  
Two (2) GFCI Circuit Breakers @ 20 amps  
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)  
Terminal legs “Oand “Groundare considered bonded  
grounds  
1Ø AND 3Ø,  
NEUTRAL  
GROUND  
TERMINAL  
480 -120 VAC  
OUTPUT TERMINALS  
TERMINAL  
HARD WIRE  
HOOKUP PANEL  
U
V
W
O
BLACK  
RED  
BLUE  
WHITE GREEN  
CIRCUIT BREAKERS  
FOR CS-6369 TWIST  
LOCK RECEPTACLES  
CIRCUIT BREAKERS  
FOR GFCI RECEPTACLES  
120 VAC, 20 AMP  
GFCI RECEPTACLES  
Y
W
X
CS-6369  
TWIST-LOCK  
AUX. POWER RECEPTACLES  
240/139V, 50 AMPS  
Figure 6. Output Terminal Panel  
page 20 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL paNeL faMiLiariZatiON  
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.  
120 vac gFci receptacles  
There are two 120VAC, 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.  
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.  
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 9. Voltage Regulator Control Knob  
Figure 7. G.F.C.I. Receptacle  
Twist lock dual voltage 120/240 vac receptacles  
There are three 240/139V, 50 amp auxiliary twist-lock (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  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL paNeL faMiLiariZatiON  
connecting loads  
over current relay  
Loads can be connected to the generator by the output  
Terminal lugs or the convenience receptacles (Figure 10).  
Make sure to read the operation manual before attempting  
to connect a load to the generator.  
An over current relay (Figure 11) is connected to the main  
circuit breaker. In the event of an overload, both the circuit  
breaker and the over current relay may trip. If the circuit  
breaker can not be reset, the reset button on the over  
current relay must be pressed. The over current relay is  
located in the control box.  
To protect the output terminals from overload, a 3-pole,  
600A main circuit breaker is provided.Make sure to switch  
all circuit breakers to the oFF position prior to starting  
the engine.  
Figure 11. Over Current Relay  
NOTICE  
Figure 10. Connecting Loads  
Remember the overcurrent relay monitors the current  
flowing from the u,v, and W output Terminal lugs  
to the load.  
In the event of a short circuit or over current condition,  
it will automatically trip the 600 amp main breaker.  
To restore power to the outputTerminal panel, press  
the reset button on the overcurrent relay and place the  
main circuit breaker in the closed position (on).  
page 22 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
LOaD appLiCatiON  
single phase load  
Three phase load  
Always be sure to check the nameplate on the generator  
and equipment to insure the wattage, amperage, frequency,  
and voltage requirements are satisfactorily supplied by the  
generator for operating the equipment.  
When calculating the power requirements for 3-phase  
power use the following equation:  
Generally, the wattage listed on the nameplate of the  
equipment is its rated output. Equipment may require  
130—150% more wattage than the rating on the nameplate,  
as the wattage is influenced by the efficiency, power factor  
and starting system of the equipment.  
NOTICE  
If 3Ø load (kVA) is not given on the equipment  
nameplate, approximate 3Ø load may be determined  
by multiplying voltage by amperage by 1.732  
NOTICE  
If wattage is not given on the equipment’s name plate,  
approximate wattage may be determined by multiplying  
nameplate voltage by the nameplate amperage.  
NOTICE  
Motors and motor-driven equipment draw much greater  
current for starting than during operation.  
WATTS = VOLTAGE x AMPERAGE  
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.  
The power factor of this generator is 0.8.SeeTable 5 below  
when connecting loads.  
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.  
Table 5. power Factor By load  
Type of load  
power Factor  
Single-phase induction motors  
0.4-0.75  
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.  
Electric heaters, incandescent lamps  
Fluorescent lamps, mercury lamps  
1.0  
0.4-0.9  
Electronic devices, communication  
equipment  
When connecting an electric drill or other power tools,  
pay close attention to the required starting current  
capacity.  
1.0  
0.8  
Common power tools  
When connecting ordinary power tools, a capacity of up to  
the generating set’s rated output (kW) multiplied by 0.8 can  
be used.  
Table 6. cable selection (60 hz, single phase operation)  
load in Watts  
maximum allowable cable length  
current  
in  
amperes  
at 100  
volts  
at 200  
volts  
#10 Wire #12 Wire #14 Wire #16 Wire  
danger  
2.5  
5
300  
600  
1000 ft.  
500 ft.  
350 ft.  
250 ft.  
150 ft.  
125 ft.  
600 ft.  
300 ft.  
200 ft.  
150 ft.  
100 ft.  
75 ft.  
375 ft.  
200 ft.  
125 ft.  
100 ft.  
65 ft.  
250 ft.  
125 ft.  
100 ft.  
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.  
600  
1200  
1800  
2400  
3600  
4800  
7.5  
10  
15  
20  
900  
1200  
1800  
2400  
50 ft.  
CAUTION: Equipment damage can result from low voltage  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr OUtpUts  
generaTor ouTpuT volTages  
maximum amps  
A wide range of voltages are available to supply voltage  
for many different applications. Voltages are selected by  
applying jumpers (6) to the voltage change-over board  
(Figure 12). To obtain some of the voltages as listed in  
Table 7 (see below) will require a fine adjustment using  
the voltage regulator (VR) control knob located on the  
control panel.  
Table 8 shows the maximum amps the generator can  
provide. do noT exceed the maximum amps as listed.  
Table 8. generator maximum amps  
dca220sscu/  
model  
dca220sscu4i  
rated voltage  
maximum amps  
voltage change-over Board  
Single Phase 120 Volt 488.9 amps (4 wire)  
Single Phase 240 Volt 244.4 amps (4 wire)  
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.  
Three Phase 240 Volt  
Three Phase 480 Volt  
529 amps  
264 amps  
Figure 12. Voltage Change-Over Board  
cauTion  
never attempt to place jumper plates on the voltage  
change-over board while the generator is in operation.  
There exist the possibility of electrocution, electrical  
shock or burn, which can cause severe bodily harm  
or even death!  
Table 7. voltages available  
uvWo output  
Terminal lugs  
voltage change-over Board  
3-phase 240/139v position  
voltage change-over Board  
3-phase 480/270v position  
208V  
120V  
220V  
127V  
240V  
139V  
416V  
240V  
440V  
254V  
480V  
277V  
line-line  
line-neutral  
voltage change-over Board single-phase 240/120v position  
line-neutral/  
line-line  
120V  
Line-Neutral  
240V  
Line-Line  
N/A  
N/A  
N/A  
N/A  
page 24 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr OUtpUts/GaUGe reaDiNG  
hoW To read The ac ammeTer and ac  
volTage gauges  
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.  
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 16.AC Ammeter  
Change-Over Switch  
Figure 17. AC Ammeter  
(Amp reading on U Lug)  
NOTICE  
The ammeter gauge will only show a reading when  
the Output Terminal Lugs are connected to a load  
and in use.  
Figure 13. Voltage Change-Over Board  
240/3Ø Position  
ac voltmeter gauge reading  
Place the ACVoltmeter Change-Over Switch (Figure 14)  
in theW-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.ACVoltmeter  
Change-Over Switch  
Figure15.ACVoltmeterGauge  
(VoltreadingonW-ULug)  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL paNeL CONNeCtiONs  
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  
uvWoTerminal 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.  
Figure 20. Voltage Regulator Knob  
1Ø-240v uvWoTerminal 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.  
3Ø-240v uvWoTerminal output voltages  
1. Jumper the voltage change-over board for 240V  
operation as shown in Figure 18  
Figure 21. UVWO Terminal Lugs 1Ø-240V  
Connections  
1Ø-120v uvWoTerminal output voltages  
1. Make sure the voltage change-over board is jumpered  
for 240V operation as shown in Figure 18.  
Figure 18. Voltage Change-Over Board 240V  
Configuration  
2. Adjust voltage regulator knob (Figure 20) for an output  
of 208V to obtain 120V at the UVWO terminals.  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 19.  
3. Connect the load wires to the UVWO terminals as  
shown in Figure 22.  
Figure 19. UVWO Terminal Lugs  
Figure 22. UVWO Terminal Lugs 1Ø-120V  
Connections  
page 26 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL paNeL CONNeCtiONs  
3Ø-480v uvWoTerminal output voltages  
1Ø-480v uvWoTerminal output voltages  
1. Jumper the voltage change-over board for 480V  
operation as shown in Figure 23. This configuration  
uses 6 jumper plates in 3 different positions.Remember  
there are 2 jumper plates at every position. Every  
jumper plate must be used.  
1. Make sure the voltage change-over board is jumpered  
for 480V operation as shown in Figure 23.  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 25.  
Figure 25. UVWO Terminal Lugs 1Ø-480V  
Connections  
Figure 23. Voltage Change-Over Board 480V  
Configuration  
1Ø-277v uvWoTerminal output voltages  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 24.  
1. Make sure the voltage change-over board is jumpered  
for 480V operation as shown in Figure 23.  
2. Connect the load wires to the UVWO terminals as  
shown in Figure 26.  
Figure 24. UVWO Terminal Lugs 3Ø-480V  
Connections  
NOTICE  
Figure 26. UVWO Terminal Lugs 1Ø-277V  
Connections  
alWaYs make sure that the connections to the UVWO  
terminals are secure and tight.The possibility of arcing  
exists, that could cause a fire.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNspeCtiON/setUp  
circuiT BreaKers  
Fuel checK  
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.  
danger  
Fuel spillage on a hot engine can cause  
a fire or explosion.If fuel spillage occurs,  
wipe up the spilled fuel completely to  
prevent fire hazards. never smoke  
around or near the generator.  
refilling the Fuel system  
luBricaTion oil  
cauTion  
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.  
onlY properly trained personnel who have read  
and understand this section should refill the fuel tank  
system.  
This generator has an internal fuel tank located inside  
the trailer frame and may also be equipped with an  
environmental fuel tank (Figure 28). alWaYs fill the fuel  
tanks with clean fresh #2 diesel fuel. do noT fill the fuel  
tanks beyond their capacities.  
Figure 27. Engine Oil Dipstick  
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.  
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.  
Generator Internal Fuel Tank  
®
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  
Trailer Fuel Tank  
Figure 28. Internal Fuel Tank System  
page 28 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNspeCtiON/setUp  
4. Open cabinet doors on the “right side” of the generator  
(from generator control panel position). Remove fuel  
cap and fill tank (Figure 30).  
refueling procedure:  
Warning  
diesel fuel and its vapors are dangerous  
to your health and the surrounding  
environment. Avoid skin contact and/or  
inhaling fumes.  
3. levelTanks — Make sure fuel cells are level with the  
ground. Failure to do so will cause fuel to spill from the  
tank before reaching full capacity (Figure 29).  
cauTion  
alWaYs place trailer on firm level ground before  
refueling to prevent spilling and maximize the amount  
of fuel that can be pumped into the tank.  
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).  
DO NOT fill on  
unlevel ground  
!
!
=
Level Ground  
Level Ground  
Figure 29. Only Fill on Level Ground  
NOTICE  
Figure 31. Full Fuel Tank  
onlY use #2 diesel fuel when refueling.  
cauTion  
do noT overFill fuel system. Leave room for fuel  
expansion. Fuel expands when heated (Figure 32).  
Figure 32. Fuel Expansion  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNspeCtiON/setUp  
coolanT (anTiFreeze/summer coolanT/  
WaTer)  
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.  
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.  
air cleaner  
Warning  
Periodic cleaning/replacement is necessary. Inspect air  
cleaner in accordance with the cummins engine owner’s  
manual.  
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.  
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.  
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 “Lmarkings.  
The fan belt tension is proper if the fan belt bends 10 to 15  
mm (Figure 33) when depressed with the thumb as shown  
below.  
Table 10. coolant capacity  
Engine and Radiator  
Reserve Tank  
11.4 gal (43 liters)  
N/A  
operation in Freezing Weather  
When operating in freezing weather, be certain the proper  
amount of antifreeze (Table 11) has been added.  
Figure 33. Fan Belt Tension  
cauTion  
Table 11. anti-Freeze  
operatingTemperatures  
never place hands near the belts or fan  
while the generator set is running.  
Freezing Point  
Vol %  
Anti-Freeze  
°C  
°F  
50  
-37  
-34  
NOTICE  
When the antifreeze is mixed with water, the antifreeze  
mixing ratio must be less than 50%.  
page 30 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iNspeCtiON/setUp  
When connecting battery do the following:  
BaTTerY  
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.  
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.  
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.  
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.  
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.  
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.  
cauTion  
Inadequate battery connections may cause poor  
starting of the generator, and create other malfunctions.  
Before charging the battery with an external electric source,  
be sure to disconnect the battery cables.  
Battery cable installation  
alTernaTor  
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.  
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.  
cauTion  
alWaYs disconnect the negative terminal FirsT and  
reconnect negative terminal lasT.  
Wiring  
Inspect the entire generator for bad or worn electrical wiring  
or connections. If any wiring or connections are exposed  
(insulation missing) replace wiring immediately.  
piping and hose connecTion  
Inspect all piping, oil hose, and fuel hose connections for  
wear and tightness. Tighten all hose clamps and check  
hoses for leaks.  
Figure 34. Battery Connections  
If any hose (fuel or oil) lines are defective replace them  
immediately.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr start-Up prOCeDUre (MaNUaL)  
BeFore sTarTing  
sTarTing (manual)  
1. Place the engine speed switch (Figure 37) in the LOW  
(down) position.  
cauTion  
The engine’s exhaust contains harmful emissions.  
alWaYs have adequate ventilation when operating.  
Direct exhaust away from nearby personnel.  
Figure 37. Engine Speed Switch (Low)  
Warning  
2. Place the Auto-Off/Reset Manual Switch in the  
manual position to start the engine (Figure 38).  
never manually start the engine with the main, gFci  
or auxiliary circuit breakers in the on (closed) position.  
1. Place the main, g.F.c.i., and aux. circuit breakers  
(Figure 35) in the oFF position prior to starting the  
engine.  
Figure 38. Auto-Off/Reset Manua;Switch  
(Manual Position)  
NOTICE  
If engine fails to start in a specified number attempts,  
the shutdown lamp will illuminate and the Auto-Off/  
Reset Switch must be place inthe Off/Reset position  
before the engine can be restarted.  
Figure 35. Main, Aux. and GFCI  
Circuit Breakers (OFF)  
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..  
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.  
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.  
4. Tighten terminal nuts securely to prevent load wires  
from slipping out.  
5. Close all engine enclosure doors (Figure 36).  
Figure 39. Engine Speed Switch (High)  
4. The generator’s frequency meter (Figure 40) should be  
displaying the 60 cycle output frequency in herTz.  
CORRECT  
INCORRECT  
Figure 36. Engine Enclosure Doors  
Figure 40. Frequency Meter  
page 32 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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,  
180  
140  
220  
°F  
100  
260  
WATER TEMP  
Figure 45. Coolant Temperature Gauge  
Figure 41. Voltmeter  
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.  
6. Use the voltage adjustment control knob (Figure 42)  
to increase or decrease the desired voltage.  
150  
120  
180  
60  
RPMX10  
0
210  
Figure 42. Voltage Adjust Control Knob  
SPEED  
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 46. Engine Tachometer Gauge  
11. Place the main, gFci, and aux. circuit breakers in the  
on position (Figure 47).  
Figure 43. Ammeter (No Load)  
8. The engine oil pressure gauge (Figure 44) will indicate  
the oil pressure of the engine. Under normal operating  
conditions the oil pressure is approximately 35 to 65  
psi. (193~586 kPa).  
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.  
50  
25  
75  
PSI  
0
100  
OIL PRESS  
Figure 44. Oil Pressure Gauge  
9. The coolant temperature gauge (Figure 45) will  
indicate the coolant temperature. Under normal  
operating conditions the coolant temperature should  
be between 180°~225°F (75°~95°C) (green zone).  
Figure 48. Ammeter (Load)  
13. The generator will run until manually stopped or an  
abnormal condition occurs.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr start-Up prOCeDUre (aUtO MODe)  
When starting generator in auTo mode use the “Manual  
Start-up” procedure except where noted (see below).  
sTarTing (auTo mode)  
danger  
1. Perform steps 1 through 5 in the Before Starting section  
as outlined in the Manual Starting Procedure.  
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.  
2. Place the engine speed switch (Figure 49) in the  
high position  
cauTion  
Figure 49. Engine Speed Switch (High)  
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.  
3. Place the auto off/reset manual switch (Figure 50)  
in the auTo position.  
NOTICE  
When the generator is set in the auTo mode, the  
generator will automatically start in the event of  
commercial power falling below a prescribed level  
by means of a contact closure that is generated  
automatically by a transfer switch.  
Figure 50. auto off/reset manual Switch (AUTO)  
4. Continue operating the generator as outlined in the  
Manual Start-up procedure (start at step 5).  
Warning  
When running the generator in the auTo mode,  
remember the generator can start up at any time without  
warning. never attempt to perform any maintenance  
when the generator is in the auto mode.  
cauTion  
The engine speed switch must be set to the “High”  
position when running in the auto-start mode. Failing  
to set the switch in the proper position can result in  
damage to your generator when it turns on.  
NOTICE  
When the Auto Off/Reset Manual switch is placed  
in the auTo position, the engine glow plugs will be  
warmed and the engine will start automatically.  
page 34 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr shUt-DOWN prOCeDUres  
6. Remove all loads from the generator.  
Warning  
7. Inspect entire generator for any damage or loosening of  
components that may have occurred during operation.  
never stop the engine suddenly except in an  
emergency.  
emergencY shuTdoWn procedure  
normal 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.  
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 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.  
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).  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MaiNteNaNCe  
10 hrs  
dailY  
1000  
hrs  
Table 12. inspection/maintenance  
250 hrs 500 hrs  
Check Engine Fluid Levels  
Check Air Cleaner  
X
X
X
X
X
X
Check Battery Acid Level  
Check Fan Belt Condition  
Check for Leaks  
Check for Loosening of Parts  
Replace Engine Oil and Filter * 1  
Clean Air Filter  
X
X
engine  
Check Fuel Filter/Water Separator Bowl  
Clean Unit, Inside and Outside  
Change Fuel Filter  
Clean Radiator and Check Coolant Protection Level*2  
Replace Air Filter Element * 3  
Check all Hoses and Clamps * 4  
Clean Inside of Fuel Tank  
X
X
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms  
X
generator  
Check Rotor Rear Support Bearing  
Replace engine oil and filter at 100 hours, first time only.  
X
1
*
2
*
Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.  
Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).  
If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,  
3
*
4
*
with no sags or dips that could collect moisture and/or oil.  
general inspecTion  
Prior to each use, the generator should be cleaned and  
inspected for deficiencies. Check for loose, missing or  
damaged nuts, bolts or other fasteners. Also check for  
fuel, oil, and coolant leaks. Use Table 12 as a general  
maintenance guideline engine side (Refer to the Engine  
Instruction Manual)  
air cleaner  
Every 250 hours: Remove air cleaner element (Figure 55)  
and clean the heavy duty paper element with light spray of  
compressed air. Replace the air cleaner as needed.  
Figure 55. Air Cleaner/Indicator  
NOTICE  
air cleaner with dust indicator  
The air filter should not be changed until the indicator  
reads red. Dispose of old air filter. It may not be  
cleaned or reused..  
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.  
page 36 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
FuelTanK 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 addiTion  
Add diesel fuel (the grade may vary according to season  
and locations).  
Fuel hoses — inspect nylon and rubber hoses for signs  
of wear, deterioration and hardening.  
removing Water from the Fuel Tank  
FuelTank lining — inspect the fuel tank lining for signs  
of excessive amounts of oil or other foreign matter.  
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.  
replacing Fuel Filter  
Replace the fuel filter cartridge with new one every 500  
hours or so.  
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.  
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.  
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.  
Vent any air  
air removal  
If air enters the fuel injection system of a diesel engine,  
starting becomes impossible. After running out of fuel,  
or after disassembling the fuel system, bleed the system  
according to the following procedure. See the cummins  
engine manual for details.  
Figure 56. Fuel Tank Cleaning  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MaiNteNaNCe  
To restart after running out of fuel, turn the switch to the  
on” position for 15-30 seconds.Try again, if needed.This  
unit is equipped with an automatic air bleeding system.  
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.  
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.  
Figure 57. Radiator Cleaning  
Flushing ouT radiaTor and replacing  
coolanT  
generaTor sTorage  
For long term storage of the generator the following is  
recommended:  
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.  
Drain the fuel tank completely.Treat with a fuel stabilizer  
if necessary.  
Check hoses for softening and kinks. Check clamps for  
signs of leakage.  
Completely drain the oil from the crankcase and refill if  
necessary with fresh oil.  
Tighten both cocks and replace the overflow tank.  
Clean the entire generator, internal and external.  
Cover the generating set and store in a clean, dry place.  
Disconnect the battery.  
Replace with coolant as recommended by the engine  
manufacturer.  
Close radiator cap tightly.  
Make sure engine coolant is at proper level.  
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.  
If generator is mounted on a trailer, jack trailer up and  
place on blocks so tires do not touch the ground or block  
and completely remove the tires.  
Warning  
Allow engine to cool when flushing out  
radiator. Flushing the radiator while hot  
could cause serious burns from water or  
steam.  
page 38 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MaiNteNaNCe  
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.  
JacKeTWaTerheaTerandinTernalBaTTerY  
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.  
NOTICE  
To ensure adequate starting capability, always have  
power applied to the generator's internal battery  
charger..  
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  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MaiNteNaNCe  
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.  
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.  
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.  
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.  
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.  
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.  
This maintenance action will be shown on the LCD display  
(DPF Warning Symbol) and the AMBER pre-alarm LED on  
the ECU control panel will be ON (lit). See Figure 59.  
ECU  
Series 800 Controller  
Engine Started  
diesel particulate Filter (dpF)  
DPF STAT  
Shutdown  
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.  
Pre-Alarm  
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.  
Alarm Screen  
Acknowledge Change  
Program  
Exit  
Option  
passive regeneration — Occurs during normal  
operation, typically under heavy load applications. Soot  
is oxidized faster than it is collected.  
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.  
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.  
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.  
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.  
page 40 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MaiNteNaNCe  
Forced regeneraTion procedure  
ECU  
Series 800 Controller  
DPF STAT  
Follow the steps below to initiate a forced regeneration:  
Engine Started  
1. Verify that the amBer pre-alarm LED is on or  
Flashing and the DPF symbol is shown on the  
ECU display.  
Shutdown  
Pre-Alarm  
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.  
Alarm Screen  
Acknowledge Change  
Program  
Exit  
Option  
5. Press and hold the request until the regen acTive  
message is displayed on the screen, then release.  
Figure 60. ECU DPF Engine Shutdown  
NOTICE  
6. Once activated, regeneration will start automatically  
and the engine idling speed will increase through the  
forced regeneration cycle. This process will last  
anywhere from 30 minutes to 1-1/2 hours.  
If the red engine shutdown LED is ever on (Figure 60),  
Cummins recommends that the DPF be removed,  
cleaned or replaced. In addition the shutdown code  
must be cleared. To clear the code, the ECM must  
be reset by a licensed Cummins Engine Service  
Technician, using Cummins service software.  
NOTICE  
During the regeneration cycle the High  
Exhaust System Temperature (hesT)  
symbol may be displayed. Display of  
this symbol can be considered normal  
during the regeneration period.  
NOTICE  
Soot and ash will accumulate in the DPF over time and  
must be cleaned. The ash is a result 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).  
ENGINE  
EXHAUST (OUT)  
DIESEL PARTICULATE  
FILTER (DPF)  
Figure 61. Typical DOC/DPF Unit  
DIESEL OXIDATION  
CATALYST (DOC)  
ENGINE  
EXHAUST (IN)  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
traiLer MaiNteNaNCe  
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.  
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.  
9. Tire ply — The tire ply (layers) number is rated in  
letters; 2-ply,4-ply,6-ply, etc.  
Remember periodic inspection of the trailer will ensure safe  
towing of the generator and will prevent personal injury and  
damage to the equipment.  
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.  
The definitions below describe some of the major  
components of a typical trailer that would be used with  
the generator.  
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.  
1. Fuel cell — Provides an adequate amount of fuel for  
the equipment in use. Fuel cells must be empty when  
transporting equipment.  
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.  
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).  
14. suspension — Protects the trailer chassis from shocks  
transmitted through the wheels. Types of suspension  
used are leaf, Q-flex, and air ride.  
4. Frame length — Measurement is from the ball hitch  
to the rear bumper (reflector).  
5. FrameWidth — Measurement is from fender to fender  
15. electrical — Electrical connectors (looms) are  
provided with the trailer so the brake lights and turn  
signals can be connected to the towing vehicle.  
6. Jack stand Trailer support device with maximum  
pound requirement from the tongue of the trailer.  
16. application — Indicates which units can be employed  
on a particular trailer.  
7. coupler Type of hitch used on the trailer for towing.  
page 42 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
traiLer MaiNteNaNCe  
BraKes  
hydraulic surge Brakes  
Trailer brakes should be inspected the first 200 miles of  
operation.This will allow the brake shoes and drums to seat  
properly.After the first 200 mile interval, inspect the brakes  
every 3,000 miles. If driving over rough terrain, inspect the  
brakes more frequently.  
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 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.  
Figure 62. Hydraulic Brake Components  
4. With a screwdriver or standard adjusting tool, rotate  
the star wheel of the adjuster assembly to expand the  
brake shoes.  
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.  
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.  
Periodically check and test the surge “actuator” to make sure  
that it is functioning correctly.Never use an undersize actuator.  
8. Repeat steps 1 through 7 on the remaining brakes.  
Table 13. hydraulic Brake Troubleshooting  
symptom  
possible cause  
solution  
No Brakes  
Brake line broken or kinked?  
Brake lining glazed?  
Repair or replace.  
Reburnish or replace.  
Correct weight.  
Trailer overloaded?  
Weak Brakes or Brakes Pull to  
One Side  
Brake drums scored or grooved?  
Tire pressure correct?  
Machine or replace.  
Inflate all tires equally.  
Match tires.  
Tires unmatched on the same axle?  
Brake components loose, bent or  
broken?  
Replace components.  
Locking Brakes  
Noisy Brakes  
Brake drums out-of-round?  
System lubricated?  
Replace.  
Lubricate.  
Brake components correct?  
Replace and correct.  
Install new shoes and  
linings.  
Brake lining thickness incorrect or  
not adjusted correctly?  
Dragging Brakes  
Replace rubber parts  
fill with dot 4 fluid.  
Enough brake fluid or correct fluid?  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
traiLer MaiNteNaNCe  
Tires/Wheels/lug nuTs  
suspension  
Tires and wheels are a very important and critical  
components of the trailer.When specifying or replacing the  
trailer wheels it is important the wheels, tires, and axle are  
properly matched.  
The leaf suspension springs and associated components  
(Figure 63) should be visually inspected every 6,000 miles  
for signs of excessive wear, elongation of bolt holes, and  
loosening of fasteners. Replace all damaged parts  
(suspension) immediately.Torqued suspension components  
as detailed in Table 15.  
cauTion  
alWaYs wear safety glasses when  
removing or installing force fitted parts.  
Failure to comply may result in serious  
injury.  
cauTion  
do noT attempt to repair or modify a  
wheel. do noT install in inner tube to  
correct a leak through the rim. If the rim  
is cracked, the air pressure in the inner  
tube may cause pieces of the rim to explode (break off)  
with great force and cause serious eye or bodily injury.  
Figure 63. Major Suspension Components  
Tire Wear/inflation  
Tire inflation pressure is the most important factor in tire  
life. Pressure should be checked cold before operation do  
noT bleed air from tires when they are hot!.Check inflation  
pressure weekly during use to insure the maximum tire life  
and tread wear.  
Table 15. suspension Torque requirements  
item  
Torque (Ft.-lbs.)  
Min-30 Max-35  
Min-45 Max-60  
Min-45 Max-60  
3/8" U-Bolt  
7/16" U-Bolt  
1/2" U-Bolt  
Table 14 (Tire Wear Troubleshooting) will help pinpoint the  
causes and solutions of tire wear problems.  
Snug fit only. Parts must rotate freely.  
Locking nuts or cotter pins are  
Shackle Bolt  
Spring Eye Bolt  
Table 14. Tire Wear Troubleshooting  
provided to retain nut-bolt assembly.  
Wear pattern  
cause  
solution  
Shoulder Type  
Shackle Bolt  
Min-30 Max-50  
Adjust pressure to particular  
load per tire manufacturer.  
Center Wear Over inflation.  
Edge Wear Under inflation.  
Adjust pressure to particular  
load per tire manufacturer.  
Make sure load does not  
exceed axle rating.  
Align wheels.  
Loss of camber  
Side Wear  
or overloading.  
Toe Wear  
Cupping  
Incorrect toe-in.  
Out-of-balance.  
Align wheels.  
Check bearing adjustment  
and balance tires.  
Wheel lockup and Avoid sudden stops when  
tire skidding. possible and adjust brakes.  
Flat Spots  
page 44 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
First pass  
FT-lBs  
second pass  
FT-lBs  
Third pass  
FT-lBs  
Wheel size  
12"  
13"  
14"  
15"  
16"  
20-25  
20-25  
20-25  
20-25  
20-25  
35-40  
35-40  
50-60  
50-60  
50-60  
50-65  
50-65  
90-120  
90-120  
90-120  
Figure 64. Wheel Lug Nuts  
Tightening Sequence  
NOTICE  
never use an pneumatic air gun to tighten wheel  
lug nuts.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr WiriNG DiaGraM  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe WiriNG DiaGraM  
page 48 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
AC Voltmeter defective?  
Is wiring connection loose?  
Is AVR defective?  
solution  
Check output voltage using a voltmeter.  
Check wiring and repair.  
No Voltage Output  
Replace if necessary.  
Defective Rotating Rectifier? Check and replace.  
Defective Exciter Field?  
Is engine speed correct?  
Check for approximately 19 ohms across J & K on CN1  
Turn engine throttle lever to “High”.  
Low Voltage Output  
High Voltage Output  
Is wiring connections loose? Check wiring and repair.  
Defective AVR? Replace if necessary.  
Is wiring connections loose? Check wiring and repair.  
Defective AVR?  
Replace if necessary.  
Short Circuit in load?  
Over current?  
Check load and repair.  
Confirm load requirements and reduce.  
Check and replace.  
Circuit Breaker Tripped  
Defective circuit breaker?  
Over current Relay actuated? Confirm load requirement and replace.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
trOUBLeshOOtiNG DiaGNOstiCs  
The engine controller of this generator diagnoses problems  
that arise from the engine control system and the engine  
itself.  
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:  
1. With the engine stopped (oFF). Push and hold the  
Hour Check Button (Figure 69) located on the control  
panel.  
dm1 active Faults — Displays active fault messages  
and codes.  
HOUR CHECK  
BUTTON  
dm2 messages and codes — Displays messages and  
codes which previously occurred that are recorded in the  
Engine Control Module (ECM).  
last shutdown — Displays the messages and codes  
that caused the most recent shutdown.  
6. After perfoming diagnostic tests, place the Auto Off/  
Reset Manual Switch in the oFF position  
Figure 69. Hour Check Button  
2. While keeping the Hour Check Button pressed, place  
the Auto Off/Reset Manual Switch (Figure 70) in the  
manual position.  
Figure 70. Auto-Off/Reset Switch  
(Manual Position)  
3. The Hour Check Menu Screen will be displayed on  
the ECU controller.  
4. Releasing the Hour Check Button and pushing the  
Program/Exit Button on the ECU controller will return  
the controller to the main screen.  
page 50 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOtes  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
expLaNatiON Of CODe iN reMarks COLUMN  
The following section explains the different symbols and  
qTY. column  
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.  
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.  
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.  
A blank entry generally indicates that the item is not sold  
separately.Other entries will be clarified in theRemarks”  
Column.  
sample parTs lisT  
remarKs column  
no. parT no. parT name  
qTY. remarKs  
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.  
1
2%  
12345  
BOLT .....................1 .....INCLUDES ITEMS W/%  
WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY  
WASHER, 3/8 IN. ..1 .....MQ-45T ONLY  
2% 12347  
3
4
12348  
12349  
HOSE ..................A/R ...MAKE LOCALLY  
BEARING ..............1 .....S/N 2345B AND ABOVE  
assembly/Kit — All items on the parts list with the  
same unique symbol will be included when this item is  
purchased.  
no. column  
Indicated by:  
unique symbols — All items with same unique  
symbol  
“INCLUDES ITEMS W/(unique symbol)”  
(@, #, +, %, or >) in the number column belong to the  
same assembly or kit, which is indicated by a note in the  
“Remarks” column.  
serial number Break — Used to list an effective serial  
number range where a particular part is used.  
Indicated by:  
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.  
“S/N XXXXX AND BELOW”  
“S/N XXXX AND ABOVE”  
“S/N XXXX TO S/N XXX”  
specific model number use — Indicates that the part  
is used only with the specific model number or model  
number variant listed. It can also be used to show a  
part is NOT used on a specific model or model number  
variant.  
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.  
Indicated by:  
“XXXXX ONLY”  
“NOT USED ON XXXX”  
parT no. column  
numbers used — Part numbers can be indicated by a  
number, a blank entry, or TBD.  
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.  
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.  
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.  
A blank entry generally indicates that the item is not sold  
separately or is not sold by Multiquip. Other entries will  
be clarified in the “Remarks” Column.  
page 52 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
sUGGesteD spare parts  
dca220sscu/dca220sscu4i WhisperWaTT generaTor WiTh  
cummings qsB7-g6 diesel engine  
1 To 3 uniTs  
qty.  
p/n  
description  
3............Y0602015150 .......HOSE, RADIATOR, HUMP  
2............Y0602015151 .......HOSE, RADIATOR  
2............Y0602015152 .......HOSE, RADIATOR  
1............Y0602015153 ......HOSE, RADIATOR  
3............Y0602015246 .......BELT, FAN  
1............4921517................SENSOR, OIL PRESSURE  
1............Y0602211320 .......SWITCH, COOLANT LEVEL  
6............Y0602042578 .......FUEL FILTER CARTRIDGE  
6............Y0602042579 .......CARTRIDGE WATER SEPERATOR  
6............Y0602041296 .......FILTER, OIL CARTRIDGE  
3............AF55014...............ELEMENT AIR CLEANER PRIMARY  
3............AF55308...............ELEMENT AIR CLEANER SAFETY  
1............0601808803..........CIRCUIT BREAKER 1P 20A  
1............0601808804..........CIRCUIT BREAKER 2P 50A  
2............LY2DUS24VDC ....RELAY  
1............Y0601806603 .......FUSE, 150A  
1............0601806671..........(LEFT) 15A  
1............0601802131..........FUSE, (CENTER) 1A  
1............0601802133..........FUSE, (RIGHT) 5A  
1............Y0601806646 .......FUSE, 20A  
NOTICE  
Part number on this Suggested Spare Parts list may  
supersede/replace the P/N shown in the text pages of  
this book.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr assy.  
page 54 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr assy.  
no.  
1
parT no.  
C1110100302  
parT name  
ROTOR ASS'Y .........................................1............. INCLUDES ITEMS W/#  
qTY.  
remarKs  
1-1#  
1-2#  
1-3#  
1-4#  
1-4A#  
1-4B#  
1-5#  
1-6#  
1-7#  
1-8#  
FIELD ASS'Y  
RESISTOR  
RECTIFIER  
HEX. SOCKET HEAD CAP SCREW  
WASHER, LOCK  
WASHER, FLAT  
FAN  
COUPLING DISK  
WASHER, COUPLING HUB  
BALANCING PLATE.................................1............. WHEN PURCHASING BALANCING  
................................................................................ PLATE ITEM 1-11 MUST ALSO BE  
................................................................................ ORDERED  
1
1
1
2
2
2
1
9
1
0601842334  
0601823282  
0018205020  
0032005000  
0401450050  
8171070002  
8171611003  
C1164200004  
8171015003  
1-9#  
1-10#  
1-11#  
1-12#  
1-13#  
2
3
4
5
6
0012116045  
0042616000  
0601000209  
C1112500004  
0071906314  
M3163400603  
Y0343204200  
EM923344  
HEX. HEAD BOLT  
WASHER, LOCK  
BALANCING WEIGHT KIT  
BEARING FLANGE  
BEARING  
COUPING RING  
HEX. HEAD BOLT  
WASHER, LOCK  
HEX. HEAD BOLT  
WASHER, LOCK  
STATOR ASS'Y  
RUBBER SEAL  
CLAMPER  
RUBBER SEAL  
CLAMPER  
RUBBER SEAL  
HEX. HEAD BOLT  
WASHER, FLAT  
COVER  
8
8
1
1
1
1
8
8
8
8
1
1
1
1
1
1
2
2
1
2
1
6
1
1
1
4
4
4
6
1
1
4
4
4
012112040  
0042512000  
C1130000103  
0226100420  
8171323004  
0223300120  
8171323103  
0221200300  
0010110035  
031110160  
C1132200003  
0226000510  
0225000470  
0017106016  
0601850144  
C1154000002  
C1138000003  
0012110065  
0042610000  
031110160  
7
7- 1  
7- 2  
7- 3  
7- 4  
7- 5  
7- 6  
7- 7  
7- 8  
7- 9  
7- 10  
7- 11  
7- 12  
8
9
10  
10A  
10B  
11  
12  
13  
14  
RUBBER SEAL  
RUBBER SEAL  
HEX. HEAD BOLT  
GROMMET  
END BRACKET  
FIELD ASS'Y, EXCITER  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX. HEAD BOLT  
COVER, BEARING  
GASKET, BEARING  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
0017112045  
C1154400004  
C1154300004  
0010106060  
0040006000  
952404470  
14A  
14B  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr assy. (CONtiNUeD)  
page 56 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
GeNeratOr assy. (CONtiNUeD)  
no.  
15  
16  
17  
parT no.  
parT name  
qTY.  
1
8
12  
12  
2
1
1
1
1
2
4
4
1
12  
12  
1
remarKs  
C1154400103  
011106015  
012112040  
0042512000  
SUCTION COVER  
HEX. HEAD BOLT  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
COVER, FAN  
HEX. HEAD BOLT  
WASHER, FLAT  
NUT  
18  
18-1 031112230  
19  
20  
20A  
20B  
21  
22  
22A  
23  
24  
25  
26  
27  
C1132300114  
0010006030  
952404470  
020106050  
0605000012  
0030020000  
030220510  
M3163600103  
012010030  
030210250  
RUBBER SUSPENSION  
HEX. NUT  
WASHER, LOCK  
COUPL ING ADAPTER  
HEX. HEAD BOLT  
WASHER, LOCK  
SPACER, BEARING  
BEARING  
M3163700004  
0070506207  
1
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL paNeL assy.  
page 58 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL paNeL assy.  
no.  
1
2
2A  
3
4
5
6
7
8
parT no.  
parT name  
CONTROL PANEL  
SET SCREW  
E-RING  
CONTROL PANEL  
HEX. HEAD BOLT  
KNOB  
CHANGE-OVER SWITCH, AMMETER  
CHANGE-OVER SWITCH, VOLTMETER  
ECU CONTROLLER  
GAUGE UNIT ASS'Y.  
PANEL LIGHT, 24V  
MACHINE SCREW  
HEX. NUT  
PANEL LIGHT SWITCH  
PUSH BUTTON  
TOGGLE SWITCH  
SWITCH, PANEL LIGHT  
EMERGENCY STOP BUTTON  
FEQUENCY METER, 45~65 HZ @240V  
AC AMMETER, 0~400A/800A:5A  
AC VOLTMETER, 0~600V  
VOLTAGE REGULATOR, 1K OHM  
PIN  
qTY.  
1
remarKs  
M4223000503  
M9220100004  
Y0080200007  
M4223000604  
0017108040  
0601840100  
0601801040  
0601801041  
Y0602202642  
Y0602120569  
0601810171  
0027104020  
OEMAA8  
2
2
1
4
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
9
10  
11  
11A  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
0601831330  
0601831205  
82608  
0601830710  
0601831557  
0601807642  
0601808992  
0601800275  
0601840073  
0605011211  
M4246700604  
M4357200202  
WIRE HARNESS, GENERATOR  
WIRE HARNESS, ENGINE  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL BOx assy.  
page 60 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL BOx assy.  
no.  
1
2
3
4
5
6
7
8
parT no.  
M4213000212  
011008020  
M4213400104  
M4213500104  
011008020  
parT name  
qTY.  
remarKs  
CONTROL BOX  
HEX. HEAD BOLT  
BACK PANEL  
TOP PANEL  
HEX. HEAD BOLT  
SET PANEL  
HEX. HEAD BOLT  
MAGNETIC SWITCH  
MAGNETIC SWITCH  
HEX. HEAD BOLT  
RECTIFIER  
1
14  
1
1
16  
1
4
1
1
4
M4260500103  
011008020  
Y0602201456  
Y0602201457  
0016906016  
0601821370  
0027104020  
9
10  
11  
12  
13  
13A  
13B  
14  
15  
15A  
16  
17  
18  
18A  
18B  
2
2
MACHINE SCREW  
LY2DUS24VDC RELAY ...............................................................1................REPLACES P/N 0601827655  
RELAY BASE.....................................................1................REPLACES P/N 0601823109  
RE LAY CLIP .....................................................1................REPLACES P/N 0601824400  
PTF08A  
PYCA1  
0027104020  
Y0601872130  
Y0601806603  
0601815153  
0027104020  
0601802218  
0601806671  
0601802131  
MACHINE SCREW  
HOLDER, FUSE  
FUSE,150A  
TERMINAL BLOCK  
MACHINE SCREW  
HOLDER, FUSE  
2
1
1
1
2
1
1
1
1
2
3
6
1
1
2
2
1
2
6
6
1
FUSE (LEFT), 15A  
FUSE (CENTER), 1A  
FUSE (RIGHT), 5A  
MACHINE SCREW  
CURRENT TRANSFORMER  
MACHINE SCREW  
OVER CURRENT RELAY  
OVER CURRENT RELAY  
MACHINE SCREW  
18C 0601802133  
19  
20  
21  
22  
23  
24  
24A  
25  
0027103020  
0601809667  
0027106020  
Y0801820847  
0601820848  
0027104020  
OEMAA8  
HEX. NUT  
Y0601807523  
CIRCUIT BREAKER, 3P 600A  
REAR TERMINAL BUSBAR  
HEX. HEAD BOLT  
SELF-LOCKING NUT  
AUTOMATIC VOLTAGE REGULATOR  
25-1 Y0601827412  
26  
26A  
27  
014210040  
021112140  
0601820604  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL BOx assy. (CONtiNUeD)  
page 62 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CONtrOL BOx assy. (CONtiNUeD)  
no.  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
38A  
39  
40  
41  
42  
43  
44  
parT no.  
parT name  
qTY.  
4
1
remarKs  
0027105016  
M4273000003  
011208030  
8181852104  
Y0917106025  
8181853104  
M4276200004  
012210020  
MACHINE SCREW  
TERM. BD, VOLTAGE CHANGE-OVER  
HEX. HEAD BOLT  
CHANGE TERMINAL  
HEX. HEAD BOLT  
CHANGE-OVER PLATE  
CHANGE PLATE  
TIE BOLT  
4
10  
20  
6
3
26  
26  
26  
3
3
1
1
1
1
1
0041410000  
0040010000  
014210040  
WASHER, FLAT  
WASHER, LOCK  
HEX. HEAD BOLT  
SELF-LOCKING NUT  
FUSE, 20A  
STOPPER, CONTROL PANEL  
WASHER, FLAT  
SNAP PIN  
021112140  
Y0601808646  
M4213600104  
952404470  
505015300  
0330000250  
0027104020  
EDGING  
MACHINE SCREW  
2
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe aND raDiatOr assy.  
page 64 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe aND raDiatOr assy.  
no.  
1
1A  
1-1  
parT no.  
parT name  
ENGINE, CUMMINS QSB7-G6  
FAN BELT  
ELEMENT, AIR CLEANER, INNER  
ELEMENT, AIR CLEANER, OUTER  
AIR CLEANER INDICATER  
CARTRIDGE, OIL FILTER  
CARTRIDGE, FUEL FILTER  
ENGINE FOOT  
qTY.  
1
1
1
1
1
1
1
1
1
6
6
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
4
1
1
3
6
1
2
4
1
1
2
4
1
2
4
remarKs  
M4923200054  
Y0602015246  
Y0602046648  
1-1A Y0602046649  
1-2  
1-3  
1-4  
2
3
4
4A  
5
6
7
8
RBX002252  
Y0602041296  
Y0602042578  
M4303200603  
M4303200703  
0131151240  
0040012000  
M4357300103  
Y0191701800  
0605515149  
Y0602022588  
Y0602022579  
Y0379500800  
Y0603306399  
Y0605511399  
Y0603306597  
Y0603300286  
Y0602021071  
Y0602012739  
Y0602011024  
Y0343207038  
0043007000  
0043107000  
M4310201514  
0343206120  
030206150  
0043106000  
0016310025  
Y0602013263  
Y0602014823  
Y0602015150  
Y0605515258  
Y0602014822  
Y0602015151  
Y0605515257  
Y0602326067  
Y0602013262  
Y0602015152  
Y0605515256  
Y0602015153  
Y0605515259  
Y0605512198  
ENGINE FOOT  
HEX. HEAD BOLT  
WASHER, LOCK  
HARNESS CLAMP  
BLOWBY HOSE  
HOSE BAND  
ADAPTER  
90° ELBOW  
DRAIN HOSE  
HOSE JOINT  
VALVE  
CONNECTOR  
LOCKNUT  
CAP  
RADIATOR/CAC ASS'Y  
CAP, RADIATOR  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
18A  
18B  
19  
20  
20A  
20B  
21  
22  
23  
24  
24A  
25  
26  
26A  
27  
28  
29  
29A  
30  
30A  
31  
BRACKET  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX. HEAD BOLT  
TUBE, CAC HOT SIDE  
TUBE, CAC COLD SIDE  
HOSE, HUMP  
CLAMP, HOSE  
TUBE, WATER INLET  
HOSE, 70-175, L=5- 00"  
CLAMP, HOSE  
U-BOLT SET  
TUBE, WATER OUTLET  
HOSE, 70-175 L=5. 00"  
CLAMP, HOSE  
HOSE, 70-100 L=52"  
CLAMP, HOSE  
HOSE JOINT  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe aND raDiatOr assy. (CONtiNUeD)  
page 66 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNGiNe aND raDiatOr assy. (CONtiNUeD)  
no.  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
parT no.  
parT name  
qTY.  
1
1
1
6
1
1
1
1
1
2
1
2
2
2
1
remarKs  
Y0602015154  
Y0602015155  
Y0602015156  
0605515198  
Y0603307520  
Y0605511394  
Y0605512192  
0193600400  
Y0199101900  
0605515170  
Y0602211320  
Y0605000010  
0030012000  
0040012000  
M3483600104  
HOSE, 70-038 1=18"  
HOSE, 70-038 L=29.5"  
HOSE, 70-038 L=43. 5"  
HOSE BAND  
45° ELBOW  
VALVE  
HOSE JOINT  
DRAIN HOSE  
OVER FLOW HOSE  
HOSE BAND  
COOLANT LEVEL SWITCH  
RUBBER SUSPENSION  
HEX. NUT  
WASHER, LOCK  
CLAMP  
43  
43A  
43B  
44  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
7-CATO GOLD  
8-RED  
2-WHITE  
3-SPECTRUM GREY  
4-SUNBELT GREEN  
9-DESERT TAN  
5-BLACK  
THE SERIAL NUMBER MAY BE REQUIRED.  
page 68 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OUtpUt terMiNaL assy.  
no.  
1
2
3
4
5
6
7
8
parT no.  
parT name  
TERMINAL BOARD  
OUTPUT TERMINAL BOLT  
TIE BOLT  
TERMINAL PLATE  
HEX. NUT  
WASHER, LOCK  
WASHER, FLAT  
HEX. HEAD BOLT  
TERMINAL COVER  
HEX. HEAD BOLT  
HINGE  
MACHINE SCREW  
HEX. NUT  
WASHER, FLAT  
MACHINE SCREW  
HEX. NUT  
OUTPUT WINDOW  
SET SCREW  
WASHER, LOCK  
WASHER, FLAT  
RING  
TERMINAL COVER  
STAY RUBBER  
HEX. HEAD BOLT  
WASHER, FLAT  
HEX. NUT  
STAY  
MACHINE SCREW  
COVER  
HEX. HEAD BOLT  
BRACKET, CIRCUIT BREAKER  
RUBBER CUSHION  
HEX. HEAD BOLT  
CIRCUIT BREAKER, 1P, 20A  
CIRCUIT BREAKER, 2P, 50A  
RECEPTACLE, CS-6369L, 50A  
RECEPTACLE, GF-20LA, 20A  
MACHINE SCREW  
HEX. NUT  
qTY.  
1
remarKs  
C1231700003  
M9220100304  
0801830804  
3461860504  
0039316000  
0040016000  
0401450160  
0016908040  
M4236100403  
0016906016  
0605010040  
0027103010  
0207003000  
0041203000  
0027103015  
0207003000  
M4236100504  
M9220100804  
0040006000  
952404470  
8
8
3
16  
24  
32  
5
1
4
2
4
4
4
4
4
1
2
2
2
2
1
2
2
4
2
1
4
1
8
1
1
2
2
3
3
2
10  
10  
I
1
2
2
4
1
1
1
1
2
1
9
10  
11  
12  
12A  
12B  
13  
13A  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
0080200005  
M4236100703  
0805009804  
012212045  
031112230  
0030012000  
0605011505  
0027105016  
M4236400204  
0016906016  
M4260600104  
28-1 0222100150  
29  
30  
31  
32  
33  
34  
34A  
35  
36  
37  
38  
39  
40  
40A  
41  
42  
43  
44  
45  
46  
011206020  
0601808803  
0601808804  
Y0601814014  
0601814013  
7538070  
OEMAA8  
0601850275  
0601815194  
7538070  
0603306775  
7538070  
0017110025  
0040510000  
M4236100604  
M4236400304  
0016906016  
M4236400004  
M4236400104  
011206020  
GROMMET  
TERMINAL BLOCK  
MACHINE SCREW  
BLIND PLUG  
MACHINE SCREW  
HEX. HEAD BOLT  
TOOTHED WASHER  
INSULATING COVER  
BRACKET  
HEX. HEAD BOLT  
CABLE OUTLET COVER  
SUPPORTER, CABLE OUTLET COVER  
HEX. HEAD BOLT  
1
8
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Battery assy.  
page 70 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Battery assy.  
no.  
1
2
parT no.  
parT name  
BATTERY  
BATTERY BAND  
qTY.  
2
1
remarKs  
0602220199  
M9103000804  
0602220920  
3
BATTERY BOLT SET.........................................2 ...............INCLUDES ITEMS W/#  
3A#  
3B#  
4
5
6
7
8
9
WING NUT  
2
2
2
1
1
1
1
1
1
1
PLASTIC WASHER  
BATTERY SHEET  
BATTERY CABLE  
BATTERY CABLE  
BATTERY CABLE  
HEX. NUT  
TOOTHED WASHER  
HEX. HEAD BOLT  
TOOTHED WASHER  
M9310500014  
M4346900404  
M3346902104  
M4346900504  
020108060  
0040508000  
0016910025  
0040510000  
10  
11  
12  
EARTH CABLE..................................................1................MAKE LOCALLY  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MUffLer assy.  
page 72 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MUffLer assy.  
no.  
1
2
3
4
5
6
7
8
parT no.  
parT name  
DEVICE, AFTER TREATMENT  
BRACKET  
HEX. HEAD BOLT  
BAND  
HEX. HEAD BOLT  
SUPER LOCK NUT  
EXHAUST PIPE  
V-BAND CLAMP  
GASKET  
V-BAND CLAMP  
GASKET  
EXHAUST PIPE COVER  
EXHAUST PIPE BRACKET  
HEX. HEAD BOLT  
U-BOLT SET  
EXHAUST TAIL PIPE  
HARNESS CLAMP  
HEX. HEAD BOLT  
GROMMET  
EXHAUST INSULATING WRAP  
HOSE BAND  
CLAMP  
qTY.  
1
1
4
2
2
2
1
1
1
1
1
1
1
4
1
1
1
2
1
1
4
1
1
remarKs  
Y0602300240  
M4330400003  
0016910025  
M2330400704  
011008020  
0207308000  
M4333000503  
Y0602325039  
Y0602320129  
Y0602325038  
Y0602320128  
M3330400804  
M3330400903  
011008020  
0602326062  
M4333100004  
M4357300014  
011008020  
0601851736  
Y0602311130  
0605515225  
0602220911  
0016910025  
8A  
9
9A  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
HEX. HEAD BOLT  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
fUeL taNk assy.  
page 74 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
fUeL taNk assy.  
no.  
1
1-1  
2
3
4
5
6
7
8
parT no.  
parT name  
FUEL TANK  
FUEL TANK CAP  
TANK BAND  
SUPPORTER SHEET  
HEX. HEAD BOLT  
SUPER LOCK NUT  
SUCTION HOSE  
RETURN HOSE  
HOSE BAND  
CART., FUEL WATER SEPARATOR  
HEX. HEAD BOLT  
90° ELBOW  
qTY.  
1
1
2
4
2
2
1
1
4
1
2
1
1
1
1
1
remarKs  
M4363000202  
0605505070  
M4363200004  
M9310500104  
011008020  
0207308000  
0191302300  
Y0191204000  
0605515109  
Y0602042579  
014210040  
Y0602022578  
Y0602022985  
0602220911  
0016906016  
M1363400104  
0605515198  
1502025103C  
011206020  
9
10  
11  
12  
13  
13A  
14  
15  
16  
17  
18  
18A  
HOSE JOINT  
CLAMP  
HEX. HEAD BOLT  
DRAIN HOSE  
HOSE BAND  
2
1
2
1
DRAIN JOINT  
HEX. HEAD BOLT  
DRAIN BOLT  
O-RING  
0802011104  
0150000018  
1
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy.  
page 76 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy.  
no.  
1
2
3
4
4A  
5
5A  
6
7
8
parT no.  
parT name  
BASE  
COVER  
qTY.  
1
1
2
I
1
1
1
10  
10  
1
1
22  
1
15  
1
4
4
8
remarKs  
M4413000412  
M1413400004  
011008020  
M4423000512  
M4493104603  
M4423000602  
M4493104603  
011008020  
0016910025  
M4423200004  
M4493100004  
0019208020  
M4423200503  
0019208020  
M4433000212  
0010114040  
030214350  
HEX. HEAD BOLT  
FRONT FRAME  
ACOUSTIC SHEET  
FRONT FRAME  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
HEX. HEAD BOLT  
COVER, FRONT FRAME  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
TOP COVER, FRONT FRAME  
HEX. HEAD BOLT  
CENTER FRAME  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX. NUT  
8A  
9
10  
11  
12  
13  
13A  
13B  
031114260  
13C 515455840  
4
14  
14A  
14B  
0010120050  
030220510  
0041220000  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
HEX. NUT  
4
4
8
4
14C 0030020000  
15  
15A  
16  
17  
17A  
18  
19  
19A  
20  
M4443000202  
M4493302804  
0016910025  
M4443300404  
M4493302904  
0019208020  
M4443300503  
M4493303004  
020108060  
REAR FRAME  
1
1
4
1
1
14  
1
1
9
ACOUSTIC SHEET  
HEX. HEAD BOLT  
COVER, REAR FRAME  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
DUCT, REAR FRAME  
ACOUSTIC SHEET  
HEX. NUT  
21  
22  
22A  
23  
M4443200403  
M9110100204  
M9116100004  
0845031504  
DOOR, REAR FRAME  
HINGE  
WASHER  
1
2
2
2
BLIND PLUG  
ADD THE FOLLOWING DIGITS AFTER THE PART  
NUMBER WHEN ORDERING ANY PAINTED PANEL TO  
INDICATE COLOR OF UNIT:  
1-ORANGE  
6-CATERPILLAR YELLOW  
7-CATO GOLD  
8-RED  
2-WHITE  
3-SPECTRUM GREY  
4-SUNBELT GREEN  
9-DESERT TAN  
5-BLACK  
THE SERIAL NUMBER MAY BE REQUIRED.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy. (CONt.)  
page 78 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy. (CONt.)  
no.  
24  
25  
26  
27  
28  
28A  
29  
30  
31  
32  
32A  
33  
parT no.  
parT name  
HEX. HEAD BOLT  
STOPPER  
qTY.  
3
1
1
1
8
8
1
4
1
4
4
1
remarKs  
0019208020  
0601850097  
0027208025  
M4443600004  
020106050  
MACHINE SCREW  
WINDOW PLATE  
SELF-LOCKING J NUT  
WASHER, FLAT  
MANUAL PACK  
MACHINE SCREW  
DOOR HANDLE  
MACHINE SCREW  
HEX. NUT  
952404470  
0600800320  
0021806016  
M9114000002  
0021806016  
020106050  
M4463100302  
M4493503004  
0019208020  
M3310600004  
0019208020  
M4463200502  
M4493503103  
0019208020  
0017110025  
M4463200304  
Y0016908016  
M4463200603  
M4493503204  
0016908020  
M4463500204  
0019206015  
M4453200202  
M4493403604  
0019108065  
0042308000  
031108160  
ROOF PANEL  
33A  
34  
35  
36  
37  
37A  
38  
39  
40  
41  
42  
42A  
43  
44  
45  
46  
46A  
47  
47A  
47B  
48  
48A  
49  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
COVER  
HEX. HEAD BOLT  
ROOF PANEL  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
HEX. HEAD BOLT  
COVER  
HEX. HEAD BOLT  
DUCT, REAR ROOF  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
GUTTER  
HEX. HEAD BOLT  
SPLASHER PANEL  
ACOUSTIC SHEET  
HEX. HEAD BOLT  
WASHER, LOCK  
WASHER, FLAT  
SIDE DOOR  
ACOUSTIC SHEET  
SIDE DOOR  
ACOUSTIC SHEET  
1
10  
1
4
1
1
16  
4
2
12  
1
1
10  
2
8
1
1
6
6
6
M4453001403  
M4493407404  
M4453001503  
M4493407504  
1
1
1
1
49A  
ADD THE FOLLOWING DIGITS AFTER THE PART  
NUMBER WHEN ORDERING ANY PAINTED PANEL TO  
INDICATE COLOR OF UNIT:  
1-ORANGE  
6-CATERPILLAR YELLOW  
7-CATO GOLD  
8-RED  
2-WHITE  
3-SPECTRUM GREY  
4-SUNBELT GREEN  
9-DESERT TAN  
5-BLACK  
THE SERIAL NUMBER MAY BE REQUIRED.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy. (CONt.)  
page 80 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
eNCLOsUre assy. (CONt.)  
no.  
50  
50A  
51  
51A  
52  
52A  
53  
53A  
54  
54A  
55  
55A  
56  
57  
58  
59  
59A  
60  
61  
62  
63  
63A  
64  
64A  
65  
66  
67  
68  
parT no.  
parT name  
SIDE DOOR  
ACOUSTIC SHEET  
SIDE DOOR  
ACOUSTIC SHEET  
DUCT  
ACOUSTIC SHEET  
DUCT  
ACOUSTIC SHEET  
DUCT  
ACOUSTIC SHEET  
DUCT  
ACOUSTIC SHEET  
HEX. NUT  
DOOR HANDLE  
DOOR HANDLE  
MACHINE SCREW  
HEX. NUT  
GUTTER  
GUTTER  
HEX. HEAD BOLT  
HINGE  
WASHER  
HINGE  
WASHER .  
HEX. HEAD BOLT  
STOPPER  
MACHINE. SCREW  
BLIND PLUG  
qTY.  
1
1
1
1
3
3
1
1
1
1
1
1
36  
4
3
28  
28  
3
3
18  
5
5
6
6
25  
8
8
11  
remarKs  
M4453001603  
M4493407604  
M4453001703  
M4493407704  
M4453301104  
M4493407804  
M4453301204  
M4493407904  
M4453301304  
M4493408004  
M4453301404  
M4493408104  
020108060  
M9114000002  
M9113000102  
0021806018  
020106050  
M4453600004  
M4453600104  
0019206015  
0845046904  
M9116100004  
0845047004  
M9116100004  
0019208020  
0601850097  
0027208025  
0845031504  
ADD THE FOLLOWING DIGITS AFTER THE PART  
NUMBER WHEN ORDERING ANY PAINTED PANEL TO  
INDICATE COLOR OF UNIT:  
1-ORANGE  
6-CATERPILLAR YELLOW  
7-CATO GOLD  
8-RED  
2-WHITE  
3-SPECTRUM GREY  
4-SUNBELT GREEN  
9-DESERT TAN  
5-BLACK  
THE SERIAL NUMBER MAY BE REQUIRED.  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
rUBBer seaLs assy.  
page 82 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
rUBBer seaLs assy.  
no.  
1
2
3
4
5
6
7
8
parT no.  
parT name  
qTY.  
remarKs  
0229201300  
0229201200  
0228901120  
0228901260  
0228900660  
0228900795  
0228901055  
0228901200  
0228900600  
0229400630  
0228801050  
0228800590  
0228100560  
0228100370  
0222100120  
0222100180  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
SEAL RUBBER  
RUBBER SHEET  
RUBBER SHEET  
4
1
1
3
1
4
4
3
1
1
2
1
2
2
2
2
9
10  
11  
12  
13  
14  
15  
16  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NaMepLate aND DeCaLs assy.  
page 84 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NaMepLate aND DeCaLs assy.  
no.  
1-1  
1-2  
1-3  
1-4  
parT no.  
parT name  
qTY.  
remarKs  
M4550000603  
M4550000703  
M9520100304  
M9520100603  
DECAL: OPERATING PROCEDURES.............1 ................M45000060  
DECAL: DPF REGEN. PROCEDURES............1 ................M45000070  
DECAL: SAFETY INSTRUCTIONS ..................1 ................M92010030  
DECAL: CAUTION............................................2 ................M92010060  
conTrol panel and Box group...............................  
2-1  
2-2  
2-3  
2-4  
2-5  
2-6  
2-7  
2-8  
2-9  
M4550000402  
M9520000104  
M9520000204  
M9520100004  
M9520100704  
M9520200404  
M9522000504  
M9520200303  
M9520200504  
DECAL: CONTROL PANEL ..............................1 ................M4S000040  
PLATE: AMMETER CHANGE-OVER SW.........1 ................M92000010  
PLATE: VOLTMETER CHANGE-OVER SW......1 ................M92000020  
DECAL: WARNING, ELECT. SHOCK HAZ.......2 ................M92010000  
DECAL: WARNING, ARC FLASH.....................1 ................M92010070  
DECAL; OVER CURRENT RELAY...................1 ................M92020040  
DECAL: CIRCUIT BREAKER ...........................1 ................M92200050  
DECAL: SET FOR OUTPUT VOLTAGE............1 ................M92020030  
DECAL: SET FOR OUTPUT VOLTAGE (S) .....1 ................M92020050  
engine and radiaTor group...................  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
M9500000004  
M9500100004  
M9503000004  
M9503000103  
M9503100004  
M9510100004  
DECAL: 0IL DRAIN PLUG................................1 ................M90000000  
DECAL: WATER................................................1 ................M90010000  
DECAL: WARNING, ROTATING PART .............2 ................M90300000  
DECAL: WATER OIL CHECK ...........................1 ................M90300010  
DECAL: WARNING, HOT COOLANT ...............1 ................M90310000  
DECAL: CAUTION, HOT PARTS ....................1 ................M91010000  
mounT Terminal group ............................  
4-1  
4-2  
4-3  
4-4  
4-5  
4-6  
M4550000503  
M9520000004  
M9520000504  
M9520000704  
M9520100404  
M9520100503  
DECAL: RECEPT. AND CB...............................1 ................M45000050  
DECAL: GROUND ............................................2 ................M92000000  
DECAL: START CONTACT .............................1 ................M92000050  
DECAL: 3-PHASE OUTPUT TERMINAL..........1 ................M92000070  
DECAL: DANGER, HIGH VOLTAGE.................1 ................M92010040  
DECAL: WARNING...........................................1 ................M92010050  
BaTTerY group ............................................  
5-1  
5-2  
5-3  
M9500300004  
M9500300104  
M9510100403  
DECAL: -...........................................................1 ................M90030000  
DECAL:+...........................................................1 ................M90030010  
DECAL: CAUTION............................................1 ................M91010040  
MUFFLER GROUP..............................................................  
6-1  
6-2  
6-3  
M9503200004  
M9503200104  
M9504200004  
DECAL: WARNING, ENGINE EXHAUST .........1 ................M90320000  
DECAL: DANGER, EXHAUST..........................1 ................M90320010  
DECAL: WARNING, START FIRES ..................1 ................M90420000  
FUEL TANK GROUP..........................................  
7-1  
7-2  
M9501500004  
M9500500104  
DECAL: DIESEL FUEL.....................................2 ................M90150000  
DECAL: FUEL DRAIN PLUG............................1 ................M90050010  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NaMepLate aND DeCaLs assy. (CONt.)  
page 86 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NaMepLate aND DeCaLs assy. (CONt.)  
no.  
parT no.  
parT name  
enclosure group  
DECAL: MQ .......................................................1................M91020000  
qTY.  
remarKs  
8-1  
8-2  
M9510200002  
0600500090  
EMBLEM  
MACHINE SCREW  
2
4
8-2A 0021106016  
8-3  
8-4  
8-5  
8-6  
8-7  
8-8  
8-9  
M4560100704  
M4560101404  
M4560101504  
M4560101603  
M4560100003  
M4560101703  
M3550002204  
STRIPE..............................................................2................M46010070  
STRIPE..............................................................1................M46010140  
STRIPE..............................................................2................M46010150  
STRIPE..............................................................2................M46010160  
STRIPE..............................................................1................M46010000  
STRIPE..............................................................1................M46010170  
DECAL: CAUTION.............................................1................M35000220  
8-10 M9512000004  
8-11 M9510000104  
DECAL: SUPPORT HOOK ..........................2................M91200000  
DECAL: DOCUMENT BOX LOCATED ..............1................M91000010  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
terMs aND CONDitiONs Of saLe — parts  
5. Parts must be in new and resalable  
condition, in the original Multiquip  
package (if any), and with Multiquip part  
numbers clearly marked.  
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.  
PAYMENT TERMS  
Terms of payment for parts are net 30 days.  
FREIGHT POLICY  
6. The following items are not returnable:  
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.  
a. Obsolete parts. (If an item is in the  
price book and shows as being  
replaced by another item, it is  
obsolete.)  
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.  
b. Any parts with a limited shelf life  
(such as gaskets, seals, “O” rings,  
and other rubber parts) that were  
purchased more than six months  
prior to the return date.  
LIMITATIONS OF SELLER’S LIABILITY  
MINIMUM ORDER  
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.  
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.  
c. Any line item with an extended  
dealer net price of less than  
$5.00.  
d. Special order items.  
RETURNED GOODS POLICY  
e. Electrical components.  
f. Paint, chemicals, and lubricants.  
g. Decals and paper products.  
h. Items purchased in kits.  
Return shipments will be accepted and  
credit will be allowed, subject to the following  
provisions:  
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.  
1. A Returned Material Authorization  
must be approved by Multiquip prior to  
shipment.  
7. The sender will be notified of any material  
received that is not acceptable.  
8. Such material will be held for five  
working days from notification, pending  
instructions. If a reply is not received  
within five days, the material will be  
returned to the sender at his expense.  
2. To obtain a Return Material Authorization,  
a list must be provided to Multiquip  
Parts Sales that defines item numbers,  
quantities, and descriptions of the items  
to be returned.  
9. Credit on returned parts will be issued  
at dealer net price at time of the original  
purchase, less a 15% restocking  
charge.  
a. The parts numbers and descriptions  
must match the current parts price  
list.  
b. The list must be typed or computer  
generated.  
10. In cases where an item is accepted, for  
which the original purchase document  
can not be determined, the price will be  
based on the list price that was effective  
twelve months prior to the RMA date.  
c. The list must state the reason(s)  
for the return.  
Effective: February 22, 2006  
d. The list must reference the sales  
order(s) or invoice(s) under  
which the items were originally  
purchased.  
11. Credit issued will be applied to future  
purchases only.  
PRICING AND REBATES  
e. The list must include the name  
and phone number of the person  
requesting the RMA.  
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.  
3. AcopyoftheReturnMaterialAuthorization  
must accompany the return shipment.  
4. Freight is at the sender’s expense. All  
parts must be returned freight prepaid to  
Multiquip’s designated receiving point.  
page 88 — dca220sscu/4i 60 hz generaTor operaTion and parTs manual rev. #0 (10/25/12)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOtes  
dca220sscu/4i 60 hz generaToroperaTion manual rev. #0 (10/25/12) — page 89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OperatiON MaNUaL  
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  
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  
Fax: 310-943-2238  
800-421-1244  
310-537-3700  
Fax: 310-943-2249  
Technical Assistance  
800-478-1244  
mexico  
United Kingdom  
MQ Cipsa  
Multiquip (UK) Limited Head Office  
Carr. Fed. Mexico-Puebla KM 126.5  
Momoxpan, Cholula, Puebla 72760 Mexico  
Contact: [email protected]  
Tel: (52) 222-225-9900  
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223  
Fax: (52) 222-285-0420 Globe Lane,  
Dukinfield, Cheshire SK16 4UJ  
Contact: [email protected]  
Fax: 0161 339 3226  
Canada  
Multiquip  
4110 Industriel Boul.  
Laval, Quebec, Canada H7L 6V3  
Contact: [email protected]  
Tel: (450) 625-2244  
Tel: (877) 963-4411  
Fax: (450) 625-8664  
© COPYRIGHT 2012, MULTIQUIP INC.  
Multiquip Inc, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other  
trademarks are the property of their respective owners and used with permission.  
This manual MUsT accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.  
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in  
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published  
in this publication at any time without notice and without incurring any obligations.  
Your Local Dealer is:  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Murphy Network Card EMS547 User Manual
Nextar Digital Photo Frame N7 110 User Manual
NuTone Universal Remote ICA 441WHW User Manual
NXP Semiconductors Network Card OM6293 User Manual
Oki Printer 320 Turbo User Manual
Omron Blood Pressure Monitor R3 1 Plus User Manual
Onkyo Portable Speaker D 407M User Manual
Panasonic Computer Monitor BT LH900AP User Manual
Panasonic Handheld Game System FZ 10 User Manual
Panasonic Impact Driver EY7540 User Manual