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MULTIQUIP MQ Power Whisperwatt DCA220SSCU, Руководство по эксплуатации и запасным частям

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page 4 — dca220sscu/4i 60 hz generaTor • operaTion and parTs manual — rev. #0 (10/25/12) 

taBLe Of CONteNts

DCa220ssCU/ssCU4i

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ......................................... 3

Table Of Contents .................................................... 4

Safety Information .............................................. 6-11

Specifications ........................................................ 12

Dimensions ............................................................ 13

Installation ........................................................ 14-15

General Information ............................................... 16

Major Components ................................................ 17

Engine Control Unit (ECU) .................................... 18

Engine/Generator Control Panel............................ 19

Output Terminal Panel Familiarization .............. 20-22

Load Application .................................................... 23

Generator Outputs ................................................. 24

Generator Outputs/Gauge Reading ....................... 25

Output Terminal Panel Connections ................. 26-27

Inspection/Setup ............................................... 28-31

Generator Start-Up Procedure (Manual) .......... 32-33

Generator Start-Up Procedure (Auto Mode) .......... 34

Generator Shut-Down Procedures ........................ 35

Maintenance ..................................................... 36-41

Trailer Maintenance .......................................... 42-45

TTrailer Wiring Diagram ......................................... 46

Generator Wiring Diagram ..................................... 47

Engine Wiring Diagram .......................................... 48

Troubleshooting (Generator) .................................. 49

Troubleshooting Diagnostics  ................................. 50

Explanation of Code in Remarks Column.............. 52

Suggested Spare Parts ......................................... 53

Component Drawings

Generator Assembly ......................................... 54-57

Control Panel Assembly ................................... 58-59

Control Box Assembly ...................................... 60-63

Engine And Radiator Assembly ........................ 64-65

Output Terminal Assembly ................................ 66-67

Battery Assembly.............................................. 68-69

Muffler Assembly .............................................. 70-71

Fuel Tank Assembly .......................................... 72-73

Enclosure Assembly ......................................... 74-79

Rubber Seals Assembly   ................................. 80-81

Nameplate And Decals Assembly .................... 82-85

Terms And Conditions Of Sale — Parts ................ 86

 NOTICE

Specifications are subject to change without notice.

Содержание MQ Power Whisperwatt DCA220SSCU

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 90: ...0161 339 3226 Canada Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 COPYRIGHT 2012 MULTIQUIP INC Multiquip...

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