MULTIQUIP MQ Power Whisperwatt DCA220SSCU, Operation And Parts Manual

Page 1: ...find the latest revision of this publication visit our website at www mqpower com Whisperwatt Series MODEL DCA220SSCU MODEL DCA220SSCU4i 60Hz GENERATOR CUMMINS QSB7 G6 DIESEL ENGINE PARTS LIST NO M48...

Page 2: ...page 2 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 proposition 65 warning Diesel engine exhaust and some of...

Page 3: ...pen 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 yo...

Page 4: ...ocedure 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 Engi...

Page 5: ...DCA220ssCU 4i 60 hz generator operation manual rev 0 10 25 12 page 5 notes...

Page 6: ...e 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 situatio...

Page 7: ...recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result alWaYs know the location of the nearest fire extinguisher alWaYs know the location of the nearest fi...

Page 8: ...ction never tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable Wet stacking is a co...

Page 9: ...ating condition alWaYs shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating alWaYs insp...

Page 10: ...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 i...

Page 11: ...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 clothin...

Page 12: ...ge Output 4 8 Kw 2 4 kW x 2 Dry Weight 6 636 lbs 3 010 kg Wet Weight 7 496 lbs 3 400 kg Table 2 Engine Specifications Model Cummins QSB7 G6 EPA Interim Tier 4 Certified Type 4 cycle water cooled direc...

Page 13: ...A E B C D MAXIMUM LIFTING POINT 14 050 lbs 6 373 kg 220 Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 31 10 in 790 mm E 41 33 in 1 050 mm B 31 10 in 790 mm F 1...

Page 14: ...page 14 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 Installation Figure 2 Typical Generator Grounding Application...

Page 15: ...ator 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 bot...

Page 16: ...parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section When a heav...

Page 17: ...10 60 Engine Started Shutdown Pre Alarm Series 800 Controller Alarm Acknowledge Screen Change Program Exit Option ECU 1 2 3 4 5 6 7 8 11 9 10 Table 4 Generator Major Components ITEM NO DESCRIPTION 1 M...

Page 18: ...C Engine Shutdown Lamp When an engine failure has occured this lamp will blink Indicating the engine has been shutdown The diagnostic fault message will be displayed on the LCD screen D Pre Alarm Lamp...

Page 19: ...E 1 PSI OIL PRESS 0 25 50 75 100 F WATER TEMP 100 140 180 220 260 VOLTS BATTERY 6 12 18 24 30 F FUEL E F RPMX10 SPEED 0 120 150 180 210 60 Series 800 Controller ECU Engine Started Shutdown Pre Alarm...

Page 20: ...liarization The Output Terminal Panel Figure 7 is provided with the following Three 3 240 139V output receptacles 50 amp Three 3 Circuit Breakers 50 amps Two 2 120V GFCI receptacles 20 amp Two 2 GFCI...

Page 21: ...Both receptacles should be tested at least once a month Figure 7 G F C I Receptacle Twist Lock DualVoltage 120 240VAC Receptacles There are three 240 139V 50 amp auxiliary twist lock CS 6369 receptacl...

Page 22: ...Over Current Relay An over current relay Figure 11 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit bre...

Page 23: ...ctor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment...

Page 24: ...ace 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...

Page 25: ...ltage Change Over Board 240 3 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...

Page 26: ...eration as shown in Figure 18 Figure 18 Voltage Change Over Board 240V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 19 Figure 19 UVWO Terminal Lugs 3 Turn the voltag...

Page 27: ...24 Figure 24 UVWO Terminal Lugs 3 480V Connections NOTICE ALWAYS make sure that the connections to the UVWO terminals are secure and tight The possibility of arcing exists that could cause a fire 1 48...

Page 28: ...refill with the specified amount of oil as outlined in the Cummins Engine Owner s Manual Oil should be warm before draining Delo engine oil is the recommended engine oil for this generator When replac...

Page 29: ...fueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel ground 300 NOTICE ONLY use 2...

Page 30: ...can cause severe burns Table 10 Coolant Capacity Engine and Radiator 11 4 gal 43 liters Reserve Tank N A Table 11 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE W...

Page 31: ...the negative terminal FIRST and reconnect negative terminal LAST When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the Auto Off Reset Manual Swi...

Page 32: ...rcuit breakers in the ON closed position INCORRECT CORRECT Starting Manual 1 Place the engine speed switch Figure 37 in the LOW down position Figure 37 Engine Speed Switch Low 2 Place the Auto Off Res...

Page 33: ...6 kPa Figure 44 Oil Pressure Gauge 9 The coolant temperature gauge Figure 45 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 180 225 F...

Page 34: ...ning in the auto start mode Failing to set the switch in the proper position can result in damage to your generator when it turns on NOTICE When the generator is set in the AUTO mode the generator wil...

Page 35: ...to Off Reset Manual Switch Off Reset 5 Verify that all status LEDs on the ECU control panel are OFF not lit WARNING NEVER stop the engine suddenly except in an emergency 6 Remove all loads from the ge...

Page 36: ...t 3 X Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X Maintenance General Inspection Prior to each...

Page 37: ...ng a spray washer Figure 56 wash out any deposits or debris that have accumulated inside the fuel tank Figure 56 Fuel Tank Cleaning FuelTank Inspection In addition to cleaning the fuel tank the follow...

Page 38: ...cks and replace the overflow tank Replace with coolant as recommended by the engine manufacturer Close radiator cap tightly Flush the radiator by running clean tap water through radiator until signs o...

Page 39: ...sing 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...

Page 40: ...xidize the soot collected in the DPF Active regeneration requires assistance from the engine to help increase the heat level in the after treatment system Active regeneration occurs at a normal engine...

Page 41: ...he DPF is every 6 months 5000 hours Forced regeneration procedure Follow the steps below to initiate a forced regeneration 1 Verify that the AMBER pre alarm LED is ON or FLASHING and the DPF symbol is...

Page 42: ...port device with maximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc a...

Page 43: ...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 blockag...

Page 44: ...with great force and cause serious eye or bodily injury Table 14 Tire WearTroubleshooting Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacture...

Page 45: ...d 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...

Page 46: ...page 46 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 Trailer Wiring Diagram Figure 66 Trailer Towing Vehicle Wiring Diagram...

Page 47: ...DCA220ssCU 4i 60 hz generator operation manual rev 0 10 25 12 page 47 Generator Wiring Diagram Figure 67 Generator Wiring Diagram...

Page 48: ...page 48 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 Engine Wiring Diagram Figure 68 Engine Wiring Diagram...

Page 49: ...r Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 19 ohms across...

Page 50: ...k Menu Screen will be displayed on the ECU controller 4 Releasing the Hour Check Button and pushing the Program Exit Button on the ECU controller will return the controller to the main screen HOUR CHE...

Page 51: ...DCA220ssCU 4i 60 hz generator operation manual rev 0 10 25 12 page 51 notes...

Page 52: ...es not guarantee the availability of the parts listed NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order qT...

Page 53: ...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 AF553...

Page 54: ...page 54 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 GENERATOR ASSY...

Page 55: ...EARING 1 2 M3163400603 COUPING RING 1 3 Y0343204200 HEX HEAD BOLT 8 4 EM923344 WASHER LOCK 8 5 012112040 HEX HEAD BOLT 8 6 0042512000 WASHER LOCK 8 7 C1130000103 STATOR ASS Y 1 7 1 0226100420 RUBBER S...

Page 56: ...page 56 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 GENERATOR ASSY continued...

Page 57: ...D BOLT 12 18 0042512000 WASHER LOCK 12 18 1 031112230 WASHER FLAT 2 19 C1132300114 COVER FAN 1 20 0010006030 HEX HEAD BOLT 1 20A 952404470 WASHER FLAT 1 20B 020106050 NUT 1 21 0605000012 RUBBER SUSPEN...

Page 58: ...page 58 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 control panel ASSY...

Page 59: ...NTROLLER 1 9 Y0602120569 GAUGE UNIT ASS Y 1 10 0601810171 PANEL LIGHT 24V 1 11 0027104020 MACHINE SCREW 2 11A OEMAA8 HEX NUT 2 12 0601831330 PANEL LIGHT SWITCH 1 13 0601831205 PUSH BUTTON 1 14 82608 T...

Page 60: ...page 60 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 CONTROL BOX ASSY...

Page 61: ...ES P N 0601823109 13B PYCA1 RE LAY CLIP 1 REPLACES P N 0601824400 14 0027104020 MACHINE SCREW 2 15 Y0601872130 HOLDER FUSE 1 15A Y0601806603 FUSE 150A 1 16 0601815153 TERMINAL BLOCK 1 17 0027104020 MA...

Page 62: ...page 62 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 CONTROL BOX ASSY continued...

Page 63: ...0 32 Y0917106025 HEX HEAD BOLT 20 33 8181853104 CHANGE OVER PLATE 6 34 M4276200004 CHANGE PLATE 3 35 012210020 TIE BOLT 26 36 0041410000 WASHER FLAT 26 37 0040010000 WASHER LOCK 26 38 014210040 HEX HE...

Page 64: ...page 64 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 engine AND Radiator ASSY...

Page 65: ...1 11 Y0603306399 HOSE JOINT 1 12 Y0605511399 VALVE 1 13 Y0603306597 CONNECTOR 1 14 Y0603300286 LOCKNUT 1 15 Y0602021071 CAP 1 16 Y0602012739 RADIATOR CAC ASS Y 1 17 Y0602011024 CAP RADIATOR 1 18 Y034...

Page 66: ...page 66 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 engine AND Radiator ASSY continued...

Page 67: ...70 038 L 29 5 1 34 Y0602015156 HOSE 70 038 L 43 5 1 35 0605515198 HOSE BAND 6 36 Y0603307520 45 ELBOW 1 37 Y0605511394 VALVE 1 38 Y0605512192 HOSE JOINT 1 39 0193600400 DRAIN HOSE 1 40 Y0199101900 OV...

Page 68: ...25 12 output terminal ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 6 CATERPILLAR YELLOW 2 WHITE 7 CATO GOLD 3 SPECTRUM GREY 8...

Page 69: ...AL COVER 1 20 0805009804 STAY RUBBER 2 21 012212045 HEX HEAD BOLT 2 22 031112230 WASHER FLAT 4 23 0030012000 HEX NUT 2 24 0605011505 STAY 1 25 0027105016 MACHINE SCREW 4 26 M4236400204 COVER 1 27 0016...

Page 70: ...page 70 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 battery ASSY...

Page 71: ...ERY BAND 1 3 0602220920 BATTERY BOLT SET 2 INCLUDES ITEMS W 3A WING NUT 2 3B PLASTIC WASHER 2 4 M9310500014 BATTERY SHEET 2 5 M4346900404 BATTERY CABLE 1 6 M3346902104 BATTERY CABLE 1 7 M4346900504 BA...

Page 72: ...page 72 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 muffler ASSY...

Page 73: ...00503 EXHAUST PIPE 1 8 Y0602325039 V BAND CLAMP 1 8A Y0602320129 GASKET 1 9 Y0602325038 V BAND CLAMP 1 9A Y0602320128 GASKET 1 10 M3330400804 EXHAUST PIPE COVER 1 11 M3330400903 EXHAUST PIPE BRACKET 1...

Page 74: ...page 74 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 fuel tank ASSY...

Page 75: ...LT 2 5 0207308000 SUPER LOCK NUT 2 6 0191302300 SUCTION HOSE 1 7 Y0191204000 RETURN HOSE 1 8 0605515109 HOSE BAND 4 9 Y0602042579 CART FUEL WATER SEPARATOR 1 10 014210040 HEX HEAD BOLT 2 11 Y060202257...

Page 76: ...page 76 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 ENCLOSURE ASSY...

Page 77: ...LT 10 8 M4423200004 COVER FRONT FRAME 1 8A M4493100004 ACOUSTIC SHEET 1 9 0019208020 HEX HEAD BOLT 22 10 M4423200503 TOP COVER FRONT FRAME 1 11 0019208020 HEX HEAD BOLT 15 12 M4433000212 CENTER FRAME...

Page 78: ...page 78 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 ENCLOSURE ASSY cont...

Page 79: ...002 DOOR HANDLE 1 32 0021806016 MACHINE SCREW 4 32A 020106050 HEX NUT 4 33 M4463100302 ROOF PANEL 1 33A M4493503004 ACOUSTIC SHEET 1 34 0019208020 HEX HEAD BOLT 10 35 M3310600004 COVER 1 36 0019208020...

Page 80: ...page 80 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 ENCLOSURE ASSY cont...

Page 81: ...407704 ACOUSTIC SHEET 1 52 M4453301104 DUCT 3 52A M4493407804 ACOUSTIC SHEET 3 53 M4453301204 DUCT 1 53A M4493407904 ACOUSTIC SHEET 1 54 M4453301304 DUCT 1 54A M4493408004 ACOUSTIC SHEET 1 55 M4453301...

Page 82: ...page 82 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 rubber seals ASSY...

Page 83: ...901120 SEAL RUBBER 1 4 0228901260 SEAL RUBBER 3 5 0228900660 SEAL RUBBER 1 6 0228900795 SEAL RUBBER 4 7 0228901055 SEAL RUBBER 4 8 0228901200 SEAL RUBBER 3 9 0228900600 SEAL RUBBER 1 10 0229400630 SEA...

Page 84: ...page 84 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 nameplate and decals ASSY...

Page 85: ...050 ENGINE AND RADIATOR GROUP 3 1 M9500000004 DECAL 0IL DRAIN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9503000004 DECAL WARNING ROTATING PART 2 M90300000 3 4 M9503000103 DECAL WAT...

Page 86: ...page 86 dca220sscu 4i 60 hz generator operation and Parts manual rev 0 10 25 12 nameplate and decals ASSY cont...

Page 87: ...90 EMBLEM 2 8 2A 0021106016 MACHINE SCREW 4 8 3 M4560100704 STRIPE 2 M46010070 8 4 M4560101404 STRIPE 1 M46010140 8 5 M4560101504 STRIPE 2 M46010150 8 6 M4560101603 STRIPE 2 M46010160 8 7 M4560100003...

Page 88: ...r products g Items purchased in kits h The sender will be notified of any material 7 received that is not acceptable Such material will be held for five 8 working days from notification pending instru...

Page 89: ...DCA220ssCU 4i 60 hz generator operation manual rev 0 10 25 12 page 89 notes...

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