OPERATION AND PARTS MANUAL
®
WHISPERWATT™ SERIES
MODEL DCA220SSJU4F
60Hz GENERATOR
(JOHN DEERE 6068HFG09 DIESEL ENGINE)
PARTS LIST NO. M5871300204
Revision #1 (06/17/16)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
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 Inc. 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 Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free
at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or
write to:
Administrator
NHTSA
1200 New Jersey Avenue, SE
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safercar.gov.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 3
TABLE OF CONTENTS
DCA220SSJU4F 60 HZ
GENERATOR
Proposition 65 Warning............................................ 2
Reporting Safety Defects.......................................... 3
Safety Information............................................... 6-11
Specifications......................................................... 12
Dimensions............................................................. 13
Installation......................................................... 14-15
General Information................................................ 16
General Paralleling Information (Option)................ 18
Major Components................................................. 19
Engine Controller Unit (ECU 835).......................... 20
Engine/Generator Control Panel............................ 21
Basler Digital Genset Controller (Option)............... 22
Basler Digital Genset Controller (Option)............... 23
Paralleling Panel (Option).................................. 24-25
Output Terminal Panel Familiarization............... 26-28
Load Application..................................................... 29
Generator Outputs.................................................. 30
Generator Outputs/Gauge Reading........................ 31
Output Terminal Panel Connections.................. 32-33
Inspection/Setup................................................ 34-37
Generator Start-Up Procedure (Manual)........... 38-39
Generator Start-Up Procedure (Auto Mode)........... 40
Generator Shut-Down Procedures......................... 41
Maintenance...................................................... 42-49
Trailer Maintenance........................................... 50-55
Generator Wiring Diagram...................................... 56
Generator Wiring Diagram, Basler (Option)............ 57
Engine Wiring Diagram (ECU 835)......................... 58
Engine Wiring Diag. Basler DGC2020HD (Option)...... 59
Battery Charger Wiring Diagram (Option).............. 60
Water Heating Element Wiring Diagram (Option)... 61
Troubleshooting (Generator)................................... 62
Troubleshooting Diagnostics .................................. 63
Basler DGC-2020 Program Appendix (Option) ......64-81
Explanation of Code in Remarks Column.............. 82
Suggested Spare Parts.......................................... 83
Component Drawings
Generator Assembly.......................................... 84-87
Control Panel Assembly (ECU 835).................. 88-89
Control Panel Assy. (Basler DGC2020HD Option).90-91
Control Box Assembly....................................... 92-95
Control Box Assembly (Basler Option) ............. 96-97
Ethernet Cable Assembly (Basler Option) ........ 98-99
Engine And Radiator Assembly..................... 100-103
Output Terminal Assembly............................. 104-107
Camlok Panel Assembly (Option) ................. 108-109
Battery Assembly ......................................... 110-111
Muffler Assembly .......................................... 112-113
Fuel Line Routing (Plumbing) Assembly....... 114-115
Fuel Tank Assembly........................................ 116117
Enclosure 1 Assembly................................... 118-121
Enclosure 2 Assembly................................... 122-123
Rubber Seals Assembly ............................... 124-125
Water Heating Element Assembly (Option) .126-127
Battery Charger Assembly (Option) ............ 128-129
Nameplate And Decals Assembly................. 130-133
Terms And Conditions Of Sale — Parts............... 134
NOTICE
Specifications are subject to change without notice.
PAGE 4 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
NOTES
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 5
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 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
„ NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
„ NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
„ NEVER operate this equipment under the influence of
drugs or alcohol.
„ NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
„ ALWAYS know the location of the nearest
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.
GENERATOR SAFETY
DANGER
„ ALWAYS check the equipment for loosened threads or
bolts before starting.
„ DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NOTICE
„ This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
„ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
„ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
„ NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fire could result causing severe
bodily harm or even death.
WARNING
„ NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
„ NEVER lubricate components or attempt service on a
running machine.
NOTICE
„ ALWAYS ensure generator is on level ground before use.
„ ALWAYS keep the machine in proper running condition.
„ Fix damage to machine and replace any broken parts
immediately.
„ ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER
„ The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
„ The engine of this equipment
requires an adequate free
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.
WARNING
„ DO NOT place hands or fingers inside engine
compartment when engine is running.
„ NEVER operate the engine with heat shields or
guards removed.
„ Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
„ DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
„ DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
„ DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
„ NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
„ 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.
„ NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
„ Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
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.
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.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
„ State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or 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.
PAGE 8 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
SAFETY INFORMATION
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.
„ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
„ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
„ ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.
„ 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 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:
„ NEVER use fuel as a cleaning agent.
„ DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
„ Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
„ Refer to MQ Power trailer manual for additional safety
information.
„ In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
„ ALWAYS shutdown engine before transporting
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
„ The maximum speed for highway towing is 55 MPH unless
posted otherwise. Recommended off-road towing is not to
exceed 15 MPH or less depending on type of terrain.
„ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
„ Avoid sharp turns to prevent rolling.
„ Trailer should be adjusted to a level position at all times
when towing.
„ Raise and lock trailer wheel stand in up position when
towing.
„ Place chock blocks underneath wheel to prevent rolling
while parked.
„ Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
„ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
„ DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
„ The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
„ NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
„ Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Power Cord/Cable Safety
DANGER
„ NEVER let power cords or cables lay in water.
„ NEVER stand in water while AC power from the
generator is being transferred to a load.
„ NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
„ NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
„ Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
„ ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
„ ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
„ NEVER use gas piping as an electrical ground.
BATTERY SAFETY
DANGER
„ DO NOT drop the battery. There is a possibility that the
battery will explode.
„ 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.
WARNING
„ ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
„ Use well-insulated gloves when picking up the battery.
„ ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
„ ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
PAGE 10 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
SAFETY INFORMATION
„ If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
EMISSIONS INFORMATION
„ 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.
The diesel engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
contained in diesel exhaust emissions.
CAUTION
„ ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
„ ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
ENVIRONMENTAL SAFETY/DECOMMISSIONING
NOTICE
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below.
NOTICE
This engine has been certified to meet US EPA Evaporative
emissions requirements in the installed configuration.
Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe
condition.
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fines or other penalties.
Emission Control Label
The emission control label is an integral part of the emission
system and is strictly controlled by regulations.
The label must remain with the engine for its entire life.
If a replacement emission label is needed, please contact
your authorized engine distributor.
„ DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.
„ Contact your country's Department of
Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.
„ When the life cycle of this equipment is over, remove
battery and bring to appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.
„ When the life cycle of this equipment is over, it is
recommended that the trowel frame and all other metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 11
SPECIFICATIONS
Model
Type
Table 1. Generator Specifications
DCA220SSJU4F
Revolving field, self ventilated,
open protected type synchronous generator
Star with Neutral
3Ø
194 kW (242 kVA)
176 kW (220 kVA)
Armature Connection
Phase
Standby Output
Prime Output
3Ø Voltage (L-L/L-N)
208Y/120, 220Y/127, 240Y/139
Voltage Change-Over Bd. at 3Ø 240/139
3Ø Voltage (L-L/L-N)
416Y/240, 440Y/254, 480Y/277
Voltage Change-Over Bd. at 3Ø 480/277
1Ø Voltage (L-L/L-N)
N/A
Voltage Change-Over Bd. at 1Ø 240/120
Power Factor
0.8
Frequency
60 Hz
Speed
1800 rpm
Aux. AC Power
Single Phase, 60 Hz
Aux. Voltage/Output
4.8 Kw (2.4 kW x 2)
Dry Weight
7,695 lbs. (3,490 kg)
Wet Weight
8,489 lbs. (3,850 kg)
Table 2. Engine Specifications
Model
John Deere 6068HF08 Tier 4 Final Certified
4 cycle, water-cooled, direct injection, turbo-charged
Type
charged air cooled, EGR, DOC, DPF and SCR
No. of Cylinders
6 cylinders
Bore x Stroke
4.17 in. x 4.99 in. (106 mm x 127 mm)
Displacement
415 cu. in. (6.8 liter)
Rated Output
293 HP at 1800 rpm
Starting
Electric
Coolant Capacity
10.3 gal. (39 liters)1
Lube Oil Capacity
8.18 gal. (31 liters)2
Lubricating Type Oil
API service class CJ-4, John Deere Plus-50TM II
DEF Tank Capacity
14.5 gal. (55 liters)
Fuel Type
#2 Diesel Fuel (Ultra low sulfur diesel fuel only)
Fuel Tank Capacity
69 gal. (260 liters)
12.5 gal. (47.1 L)/hr at full load 9.7 gal. (36.4 L)/hr at 3/4 load
Fuel Consumption
6.9 gal. (26.1 L)/hr at 1/2 load
4.4 gal. (16.7 L)/hr at 1/4 load
Battery
12 (150Ah X 1
1
Includes engine and radiator hoses
2
Includes filters
PAGE 12 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
DIMENSIONS
C
B
MAXIMUM
LIFTING
POINT
14,050 lbs.
(6,373 kg)
TOP VIEW
A
D
E
220
SIDE VIEW
F
FRONT VIEW
Figure 1. Dimensions
G
Table 3. Dimensions
H
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
35.83 in. (910 mm)
E
43.70 in. (1,110 mm)
B
35.83 in. (910 mm)
F
137.79 in. (3,500 mm)
C
43.70 in. (1,110 mm)
G
70.86 in. (1,800 mm)
D
41.34 in. (1,050 mm)
H
51.18 in. (1,300 mm)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 13
INSTALLATION
GENERATOR
GROUND LUG
GROUND ROD FOR
EARTH GROUND.
CONNECT TO BUILDING
GROUND IF APPLICABLE
GROUND CABLE
REFERENCE
NEC 250-83 (C)
Figure 2. Typical Generator Grounding Application
PAGE 14 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
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).
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
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.
INDOOR INSTALLATION
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 8 AWG (5.3 mm2)
b. Aluminum - 6 AWG (8.4 mm2)
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
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.
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
MOUNTING
This generator has a permanent bonding conductor
between the generator stator windings and the frame.
NOTICE
NOTICE
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.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 15
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 “OpenDelta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
OPERATING PANEL
The “Operating Panel” is provided with the following:
„„ECU 835 Controller (Standard)
„„Gauge Unit Assembly
•Oil Pressure Gauge
•Water Temperature Gauge
•Charging Voltmeter
•Fuel Gauge
•Tachometer
„„Panel Light/Panel Light Switch
„„Hour Check Button
„„Auto Start/Stop Switch
„„Emergency Stop Button
„„Basler DGC2020 Digital Controller (Option)
CONTROL PANEL
The “Control Panel” is provided with the following:
„„Frequency Meter (Hz)
„„AC Ammeter (Amps)
„„AC Voltmeter (Volts)
„„Ammeter Change-Over Switch
„„Voltmeter Change-Over Switch
„„Voltage Regulator
„„3-Pole, 600 amp Main Circuit Breaker
„„“Control Box” (located behind Control Panel)
•Automatic Voltage Regulator
•Current Transformer
•Over-Current Relay
•Starter Relay
•Voltage Change-Over Board
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
„„Three 120/240V output receptacles (CS-6369), 50A
„„Three auxiliary circuit breakers, 50A
„„Two 120V output receptacles (GFCI), 20A
„„Two GFCI circuit breakers, 20A
„„Eight output terminal lugs (3Ø power)
„„Ground Lug
„„Battery Charger (Optional)
„„Camloks (Optional)
„„Jacket Water Heater (Optional)
ENGINE
This generator is powered by a 6 cylinder, 4-cycle water
cooled, direct injection, turbocharged, air cooled EGR John
Deere 6068HFG09 diesel engine. This engine is designed
to meet every performance requirement for the generator.
Reference Table 2 for engine specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERAL PARALLELING INFORMATION (OPTION)
PARALLELING
Paralleling is the sharing of a load between two generator
sets or more.
LOAD SHARING
Load sharing is defined as the proportional division of the
kW and kVAR total load between multiple generator sets
in a paralleled system.
Load sharing is essential to avoid overloading and stability
problems on the systems’ generator sets.
ACTIVE POWER (KW) LOAD SHARING
When generator sets operate in parallel, the engine speed
governor of each generator set determines the proportional
sharing of the total active power requirements (kW) of the
systems’.
The kW load sharing is achieved by increasing or decreasing
fuel to the systems’ engines. As the fuel to the engine of
one generator set in a group is increased it will not lead to
an increase in speed and hence frequency (as it would if it
were operating alone) but it will lead to an increase in the
proportion of the total kW load that it will deliver.
As the fuel to the engine of one generator set in a group
is decreased it will not lead to a decrease in speed and
hence frequency (as it would if it were operating alone) but
it will lead to a decrease in the proportion of the total kW
load that it will deliver.
The control system of the generator sets (via the engine
speed control system) monitors and controls the sharing
of the total kW load in proportion to the relative rating of
the engines on the systems’ generator sets.
REACTIVE POWER (KVAR) LOAD SHARING
When generator sets operate in parallel the alternator
field excitation system of each generator set controls
the proportional sharing of the total reactive power
requirements (kVAR) of the system.
The kVAR load sharing is achieved by increasing or
decreasing the field excitation to the systems’ alternators
As the field excitation of one generator set in a group is
decreased i.e. over excited it will not lead to an decrease
in voltage (as it would if it were operating alone) but It will
lead to an decrease in the proportion of the total kVAR load
it will deliver and a increase in its power factor.
An undesirable circulating reactive current (cross current)
will flow in the system if the excitation of the alternators
are not matched.
ETHERNET COMMUNICATION
Ethernet communication is the preferred method for
paralleling. This method supports breaker negotiation to
avoid simultaneous breaker closures, kW load sharing
and kVAR sharing, soft load transfers on and off loading.
The Ethernet ports are located at the output bus splash
panel area. There are two ports which are identical so either
one can be used. Using a standard Ethernet cable, interconnect units to be paralleled and or sequenced.
LOAD MANAGEMENT
These generators are set up to automatically manage load,
based on demand. Load management is only functional in
auto mode. While in auto mode, if the auto start contacts
are closed, load management is active by default. Load
management will only run the number of units needed to
support the load.
If the load demand is small, only one generator will remain
running while the other generators will be in standby mode.
If the load increases above 80% of its capacity, it will start
the next generator. The next generator priority is based on
the time remaining on the maintenance timer.
Generators with more time until scheduled maintenance will
take priority over units that are almost due for maintenance.
Once the second unit starts it will synchronize and parallel
in then ramp up to share the load. If the load levels drop
below 35% of its combined rating, the generator that is no
longer needed will ramp off, shut down and wait in standby
mode.
As the field excitation of one generator set in a group is
increased i.e. over excited it will not lead to an increase
in voltage (as it would if it were operating alone) but It will
lead to an increase in the proportion of the total kVAR load
it will deliver and a decrease in its power factor.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 17
GENERAL PARALLELING INFORMATION (OPTION)
SEQUENCING
NOTICE
Ethernet communication is required when the
generators are configured for the sequencing mode
of operation.
These generators are capable of sequencing for control
of balanced maintenance schedules. As described
above, these generators can start and stop as demand
raises or lowers. In addition, if the units get to the point of
maintenance, it will ramp off and start the next generator to
relieve it based on the time remaining on the maintenance
timer.
After maintenance is performed, the maintenance timers
should be reset to the recommended service interval. This
is usually 250 hours depending on the engine oil type.
MAINTENANCE INTERVAL
Maintenance intervals are factory set for 250 hours.
The maintenance interval timer will count down to zero
indicating that it is time for the unit to be serviced.
Once the timer counts down to zero, a pre-alarm will appear
indicating that the unit is due for maintenance. To reset the
maintenance interval back to the default time of 250 hours,
press and hold the “Reset” button for ten seconds.
To reset the maintenance interval using the reset button,
the Maintenance Due pre-Alarm must be active, and the
Basler controller must display the “Overview Screen” (Main
Screen).
If the maintenance timer has not yet expired and it is
desired to reset the unit back to 250 hours, navigate back
to the settings menu. Settings Menu->System Parameters>Engine Statistics->Hours To Maintenance.
Full Password key sequence is ^ Edit ^Edit. The set-point for
the desired hours until maintenance can now be changed.
Press edit to save.
Pre-alarm Silence allows the user to suppress the toggling
of the alarm screen when a new Pre-alarm becomes active.
While a Pre-alarm is active, pressing the Alarm Silence
button will suppress the fault display.
This happens to be very handy function when the
“Maintenance Interval” Pre-Alarm occurs. Right after the
Pre-Alarm occurs it will begin toggling between the prealarm and the overview screen.
While in this mode, pressing the reset button does not reset
the maintenance interval. In order to reset the maintenance
interval the overview screen must be selected.
Pressing the alarm silence button will stop the toggling
between the pre-alarm and the overview screen.
Once the overview screen is selected, the maintenance
interval can be reset by pressing and holding the reset
button for 10 seconds.
ANALOG LOAD SHARING
If no Ethernet cable is available or if paralleling to other
equipment with traditional analog load sharing, there is a
terminal block to connect a shielded wire pair between the
two controls. The voltage ranges are programmable with
the default value set by Multiquip at 0-3VDC, which is a
common voltage for most controllers.
Please note that when in the load sharing mode the voltage
is set to droop at 5%. This setting is programmable, but the
default setting is 5%.
When highlighted, press the “Edit” button. Username and
Password is required. User Name is A and Password is
A. Use the up arrow button () and scroll to the alpha
character A, then press edit to select.
Next, the cursor will move to the password field, press the
up arrow button () and scroll to the alpha character A,
then press edit to select.
PAGE 18 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MAJOR COMPONENTS
1
2
220
3
6
4
5
220
V
U
W
O GND
7
10
11 12
25
0
50
75
PSI
140
100
180
260
60
F
30
INCREASE
DECREASE
BATTERY
½
FUEL
24
VOLTS
6
WATER TEMP
E
18
12
220
°F
100
OIL PRESS
0
120
150
X
180
RPMX10
1
V
210
U
W
OFF
ECU
Y
SPEED
Series 800 Controller
Engine Started
Shutdown
W-U
U-V
2
W2
O
OFF
Pre-Alarm
Screen
Alarm
Acknowledge Change
Option
U2
V2
Z
3
V-W
Program/
Exit
9
Denyo
4
5
6
U1
V1
W1
8
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
1
Muffler Assembly
2
Enclosure Assembly
3
Generator Assembly
4
Battery Assembly
5
Engine Assembly
6
Fuel Tank Assembly
7
Output Terminal Assembly
8
Circuit Breaker Assembly
9
Auto Start/Stop Controller Assembly
10
Gauge Unit Assembly
11
Operating Panel Assembly
12
Voltage Change-Over Board
Figure 3. Major Components
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 19
ENGINE CONTROLLER UNIT (ECU 835)
1
ECU
Series 800 Controller
Engine Started
Shutdown
A
Pre-Alarm
B
C
D
25
0
50
75
PSI
140
100
180
260
18
12
220
°F
100
OIL PRESS
24
VOLTS
6
WATER TEMP
30
INCREASE
½
120
150
180
60
E
°F
FUEL
F
DECREASE
BATTERY
0
RPMX10
V
210
SPEED
U
W
OFF
ECU
V-W
Series 800 Controller
Engine Started
Shutdown
W-U
U-V
OFF
Pre-Alarm
Alarm
Screen
Acknowledge Change
E
Option
F G
Alarm
Screen
Acknowledge Change
Program
Exit
Option
Program
Exit
H
Figure 4. Engine Control Unit (ECU)
The definitions below describe the controls and functions
of the Engine Control Unit (Figure 4).
1. ECU 835 Controller — This auto star t/stop
controller displays the parameters and the diagnostic
troubleshooting messages of the engine, and controls
DPF regeneration.
A. ECU Display Screen — Engine fault diagnostic
messages are shown on this LCD display. screen
B. Engine Started Lamp — This lamp when lit
indicates engine is operating normally.
C. Engine Shutdown Lamp — When an engine
failure has occured this lamp will blink. Indicating
the engine has been shutdown. The diagnostic
fault message will be displayed on the LCD screen.
D. Pre Alarm Lamp — When an engine failure has
occured this lamp will blink. Indicating a pre-fault
engine condition and the possibility of engine
shutdown.The diagnostic fault message will be
displayed on the LCD screen
E. Alarm Acknowledge Button — When the engine
experiences a fault, the "Pre Alarm Lamp" or the
"Shutdown Lamp" will start blinking. Pushing this
button will confirm the fault message and the
blinking lamp will change to a solid lamp display.
The fault message will be displayed on the screen.
When multiple engine faults occur, the lamp will
continue blnking until all fault messages are
confirmed. The blinking lamp will change to a solid
lamp display all current confirmed fault messages
will scrool across the screen.
F. Screen Change Button — When this button is
pushed during operation, the screen will cycle
through each parameter screen.
G. Option Button — This button is not active. Do
not use.
H. Program/Exit Button — Pushing this button
allows the DPF Force Regen and diagnostic code
to be confirmed.
PAGE 20 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENGINE/GENERATOR CONTROL PANEL
1
3
2
4
7
25
0
50
75
PSI
A
140
100
100
180
°F
B
18
12
220
25
0
24
VOLTS
6
260
C
50
75
PSI
140
100
OIL PRESS
180
260
INCREASE
DECREASE
120
150
8
180
F
0
RPMX10
V
210
U
BATTERY
120
150
180
ECU
E
°F
FUEL
F
9
Series 800 Controller
60
0
RPMX10
Z
W2
W1
6
O
OFF
Shutdown
210
14
V1
5
3
W-U
U-V
Engine Started
V2
2
V-W
U1
4
Y
W
5
E
½
U2
1
SPEED
OFF
D
X
60
°F
FUEL
WATER TEMP
30
BATTERY
½
E
OIL PRESS
13
24
VOLTS
6
WATER TEMP
30
18
12
220
°F
100
Pre-Alarm
SPEED
6
Alarm
Screen
Acknowledge Change
12
Option
Program
Exit
10
11
Figure 5. Gauge Unit Assembly
The definitions below describe the controls and functions
of the Engine/Generator Control Panel (Figure 5).
1. Gauge Unit Assembly — This assembly houses the
various engine monitoring gauges. These gauges
indicate: oil pressure, water temperature, charging
voltmeter, fuel and engine speed RPM (tachometer).
A. Oil Pressure Gauge — During normal operation
this gauge be should read approximately 44 psi.
(303 kPa). When starting the generator the oil
pressure may read a little higher, but after the
engine warms up the oil pressure should return
to the correct pressure range.
B. Water Temperature Gauge — During normal
operation this gauge be should read between 185°
and 207°F (85°~97°C).
C. Charging Voltmeter Gauge — During normal
operation this gauge indicate minimum 26 VDC
D. Fuel Gauge — Indicates amount of diesel fuel
available.
E. Tachometer — Indicates engine speed in RPM’s
for 60 Hz operation. This meter should indicate
1800 RPM’s when the rated load is applied.
2. Panel Light — For operation at night, panel light
illuminates control panel for ease of reading meters
and gauges. Make sure oanel light switch is in the OFF
position when light is not in use.
3. Panel Light Switch — When activated will turn on
control panel light.
4. Frequency Meter — Indicates the output frequency
in hertz (Hz). Normally 60 Hz
5. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
6. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
7. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
8. Ammeter Change-Over Switch — This switch allows
the AC ammeter to indicate the current flowing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
9. Voltmeter Change-Over Switch — This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
10. Emergency Stop Switch Button — In the event
of an emergency press this button to shut down the
generator.
11. Auto/Start Switch — This switch selects either manual
or automatic operation. Center position is OFF (reset).
12. Hour Check Button — With the engine stopped, press
and hold ths button. The total running hours, fuel level,
and battery voltage will be displayed.
13. Voltage Change-Over Board — 6 jumper plates that
allows the generator to be configured for either 3Ø,
240 or 480 VAC output.
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.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 21
BASLER DIGITAL GENSET CONTROLLER (OPTION)
Figure 6. Basler DGC-2020HD
NOTICE
The Basler DGC-2020HD is an option. It replaces the
ECU 835 that comes standard with this generator. For
detailed programming information refer to the Basler
programming appendix in this manual.
PAGE 22 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DIGITAL GENSET CONTROLLER (OPTION)
The definitions below describe the controls and functions
of the Digital Genset Controller (Figure 6).
1. LCD Display — Display consists of a LCD color touch
screen. The backlit, 272X480 pixel color LCD serves
as the local information source for metering, alarms,
pre-alarms, and protective functions. Touch screen
capability provides convenient navigation through
metering and settings. Display operation is maintained
down to –4°F (−20°C).
2. Not In Auto Indicator — This red LED lights when the
DGC-2020HD is not operating in AUTO mode.
3. Alarm Indicator — This red LED lights continuously
during alarm conditions and flashes during pre-alarm
conditions.
4. Supplying Load Indicator — This green LED lights
when the generator current is greater than emergency
power supply (EPS) threshold current.
5. Programmable Indicators — These three red
LEDs light when the corresponding logic element
is set true. Logic element PROGLED 1 controls the
upper LED, PROGLED 2 controls the middle LED,
and PROGLED 3 controls the lower LED. A card is
provided for labeling the programmable indicators. See
Programmable Indicator Configuration, below.
6. Alarm Silence Pushbutton — Pressing this button
tests the DGC-2020HD indicators by exercising all
LCD pixels and lighting all LEDs.
9. Off Pushbutton and Mode Indicator. — Pressing this
button places the DGC-2020HD in Off mode.The red
Off mode LED lights when the DGC-2020HD is in Off
mode. This button also resets the Breaker Management
Pre-Alarms and all MTU ECU Alarms.
10. Run Pushbutton and Mode Indicator. — Pressing
this button places the DGC-2020HD in Run mode. The
green Run mode LED lights when Run mode is active.
11. Reset Pushbutton — This button is pressed to cancel
a settings editing session and discard any settings
changes. When pressed momentarily, this button
resets the Breaker Management Pre-Alarms and all
MTU ECU Alarms. This button is also used to reset
the Maintenance Interval when pressed for 10 seconds
while viewing Hours Until Maintenance or Maintenance
Due Pre-Alarm.
12. Arrow Pushbuttons — These four buttons are used
to navigate through the front panel display menus and
modify settings.
•The left and right arrow buttons are used to navigate
through the menu levels. The right arrow button is
pressed to move downward through the menu levels
and the left arrow button is pressed to move upward
through the menu levels.
7. Lamp Test Pushbutton — Pressing this button tests
the DGC-2020HD indicators by exercising all LCD
pixels and lighting all LEDs.
•Within a level, the up and down arrow buttons are used
to move among items within the menu level. Pressing
the down arrow button moves to items lower in the list.
Pressing the up arrow button moves to items higher
in the list.
8. Auto Pushbutton and Mode Indicator — Pressing
the Auto button places the DGC-2020HD in Auto
mode. The green Auto mode LED lights when Auto
mode is active.
•During a settings editing session, the up and down
arrow buttons are used to raise and lower the value of
the selected setting. The right and left arrow buttons
move to different digits.
While in “AUTO” the controller will be in standby
awaiting a signal to start via the remote start terminals.
While in auto, closure of the auto start contacts will
immediately start the engine. Once the generator is
up to speed and voltage it will compare its voltage to
the bus.
13. Edit Pushbutton — Pressing this button starts an
editing session and enables changes to DGC-2020HD
settings. At the conclusion of an editing session, the
Edit pushbutton is pressed again to save the setting
changes.
If the bus is dead it will immediately close the contactor
to provide power to the load(s). If the bus is already
hot from another generator it will first synchronize then
close its contactor then slowly ramp up to share load
if load were present
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 23
PARALLELING PANEL (OPTION)
Figure 7. Paralleling Panel Components
PAGE 24 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
PARALLELING PANEL (OPTION)
The definitions below describe the controls and functions
of the Paralleling Panel (Figure 7).
1. Panel Lights — For operation at night or in dark areas,
panel light illuminates paralleling panel for ease of
reading.
2. Panel Light Switch — When activated will turn on
control panel light.
3. Voltage Adjust potentiometer — The voltage adjust
potentiometer is a way to adjust the voltage up or
down for fine tuning. The adjustment sends a signal to
the controller to offset the system rated voltage (Trim
Voltage). It is important that all machines are set to the
same value when paralleling.
When first turning on the control power, the controller
will begin its boot sequence much like a computer
does. After completing the boot sequence the unit
will be ready to run or be placed in auto for auto start
applications.
For units with manual operated breakers, the breaker
will need to be reset by toggling the handle down, then
can be turned back to the “ON” position. On models
with spring charged breakers resetting the breaker is
not necessary.
6. Contactor Operation (Manual Mode) — The For
manual run applications, user action is required to get
the generator power to the output bus. Depending on
the model, some utilize contactors in series with toggle
handle circuit breakers and others have spring charged
automatic circuit breakers.
On the spring charged types, the buttons on the breaker
itself are not intended for circuit breaker operation.
For instructional purposes both will be referred to as
“contactor”.
4. Control Power Toggle Switch — The control power
switch is a master power switch for the digital controller.
The control power switch has a latch feature that
prevents powering down control power while the engine
is running.
There are two pushbuttons on the control panel for
controlling the contactor. There is a green “CLOSE
CONTACTOR” button to close the contactor and a red
“OPEN CONTACTOR” button to open the contactor.
These buttons illuminate to show the contactor status.
If the contactor is open, the red “OPEN CONTACTOR”
button will be illuminated. If the contactor is closed
the green “CLOSE CONTACTOR” button will be
illuminated.
5. Emergency Stop Button Switch — The Emergency
Stop pushbutton switch is used to stop the engine in
case of emergency or to lock out operation during
service. The emergency stop button should not be
used for routine stopping of the engine.
These buttons can sometimes be multifunctional
depending on the situation. For stand-alone operation
the buttons simply close and open the contactor as
expected. For paralleling the buttons can act a little
different.
Actuation of the Emergency stop button while the
control power is on will illuminate the light on the button
as well as display “Emergency Stop” on the controller
display. Actuating the Emergency stop button will deenergize all controller outputs and cause the engine
to stop as well as tripping the circuit breaker. This
condition is a latched condition that must be reset prior
to restarting the engine.
When the bus is already hot from another generator,
pressing the green online button will initiate a
synchronizing sequence before closing the contactor.
There will be an image of a synchro scope on the
controller display and when the voltage and phases
are matched, the contactor will close.
The procedure for resetting the emergency stop
requires several actions. Rotate the emergency stop
button to release the spring latch. To clear the latch,
the controller must be placed into the off mode by
pressing the “OFF” button. While in the “OFF” mode,
the “RESET” button must be pressed to clear the
E-STOP fault.
If there was already load on the bus the unit will slowly
ramp up load until it is sharing equally with the other
generator(s). While sharing load with other generators,
pressing the red “OPEN CONTACTOR” button once
will initiate a ramp down sequence. The unit will begin
to ramp down and when at a low level of load it will
automatically open it contactor. Pressing the red
“OPEN CONTACTOR” button twice will immediately
open the contactor.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 25
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
OUTPUT TERMINAL FAMILIARIZATION
The Output Terminal Panel (Figure 9) shown below is
provided for the connection of electrical loads. Lift up on
the cover to gain access to receptacles and terminal lugs.
The “Output Terminal Panel ” (Figure 9) is provided with
the following:
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds
„„Three (3) 240/139V output receptacles @ 50 amp
„„Three (3) Circuit Breakers @ 50 amps
„„Two (2) 120V GFCI receptacles @ 20 amp
„„Two (2) GFCI Circuit Breakers @ 20 amps
„„Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
220
1Ø AND 3Ø,
480 -120 VAC
OUTPUT TERMINALS
NEUTRAL
TERMINAL
GROUND
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 8. Output Terminal Panel
PAGE 26 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
change-over board position. Each receptacle is protected
by a 20 amp circuit breaker. These breakers are located
directly above the GFCI receptacles. Remember the load
output (current) of both GFCI receptacles is dependent on
the load requirements of the U, V, and W output terminal
lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
all three receptacles is dependent on the load requirements
of the output terminal lugs.
Turn the voltage regulator control knob (Figure 11) on
the control panel to obtain the desired voltage. Turning the
knob clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Figure 11. Voltage Regulator Control Knob
Removing the Protective Cover (Hard Wire Hookup
Panel)
The output terminal lugs are protected by a protective
cover (Figure 12). Un-screw the securing bolts (8) and
remove the cover to gain access to the output terminal lugs.
After the load wires have been securely attached to the
output terminal lugs, reinstall the protective cover, and
reinstall the retaining bolts
PROTECTIVE
TERMINAL COVER
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 240/139V, 50 amp auxiliary twist-lock (CS6369) receptacles (Figure 10) 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
RETAINING
BOLT
Figure 12. Protective Terminal Cover
(UVWO Terminal Lugs)
Figure 10. 240/139V Twist-Lock Auxiliary
Receptacles
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 27
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 13).
Make sure to read the operation manual before attempting
to connect a load to the generator.
An over current relay (Figure 14) 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.
CS-6369
TWIST-LOCK
RECEPTACLES
HARD WIRE
HOOKUP PANEL
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
LOAD
GFCI
RECEPTACLES
LOAD
GROUND
LOAD
NEUTRAL
CAMLOCKS
Figure 14. Over Current Relay
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
Figure 13. Connecting Loads
In the event of a short circuit or over current condition,
it will automatically trip the 600 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
PAGE 28 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
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 wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Table 5. Power Factor By Load
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
Common power tools
1.0
0.4-0.9
1.0
0.8
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
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
2400
4800
125 ft.
75 ft.
50 ft.
20
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
„„When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
„„When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
„„When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer itch.
CAUTION: Equipment damage can result from low voltage
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 29
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 using
the voltage change-over board (Figure 15). 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.
Voltage Change-Over Board
The voltage change-over board (Figure 15) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection n..
Table 8. Generator Maximum Amps
Rated Voltage
Maximum Amps
1Ø 120 Volt
488.9 X 2 amps (4 wire)
1Ø 240 Volt
244.4 amps (4 wire)
3Ø 240 Volt
529 amps
3Ø 480 Volt
264 amps
JUMPER
6 PLACES
X
U2
U1
4
1
Y
V2
2
V1
5
Z
W2
3
W1
6
O
Figure 15. Voltage Change-Over Board
CAUTION
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
Table 7. Voltages Available
UVWO Output
Terminal Lugs
Voltage Change-Over Board
3-Phase 240/139V Position
Voltage Change-Over Board
3-Phase 480/270V Position
3Ø Line-Line
208V
220V
240V
416V
440V
480V
1Ø Line-Neutral
120V
127V
139V
240V
254V
277V
PAGE 30 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 19)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 20). This process can be repeated for
terminals V and W.
Before taking a reading from either gauge, configure the
Voltage Change-Over Board (Figure 16) which produces
the desired output voltage.
JUMPER
6 PLACES
X
U2
NOTICE
Y
V2
2
V1
5
Z
W2
3
Figure 20. AC Ammeter
(Amp reading on U Lug)
U1
4
1
Figure 19. AC Ammeter
Change-Over Switch
W1
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
6
O
Figure 16. Voltage Change-Over Board240/3Ø Position
AC Voltmeter Gauge Reading
Place the AC Voltmeter Change-Over Switch (Figure 17)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 18).
Figure 17. AC Voltmeter
Change-Over Switch
Figure 18. AC Voltmeter Gauge
(Volt reading on W-U Lug)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 31
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the placement of the jumpers plates (6) on
the Voltage Change-Over Board and the adjustment of
the Voltage Regulator Control Knob.
Remember the voltage change-over board determines the
range of the output voltage and can be configured in two
different positions that provide 6 different output voltages
at the UVWO output terminals. The generator is shipped
from the factory in the 240V configuration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
3Ø-240V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 240V
operation as shown in Figure 21
3. Turn the voltage regulator knob (Figure 23) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
Figure 23. Voltage Regulator Knob
1Ø-240V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as
shown in Figure 24.
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
JUMPER
6 PLACES
X
U2
240V
240V
U1
4
1
Y
2
V1
5
SINGLE-PHASE
240 VAC (LOAD CONNECTIONS)
Z
W2
3
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
240V
V2
Figure 24. UVWO Terminal Lugs
1Ø-240V Connections
W1
6
O
1Ø-120V UVWO Terminal Output Voltages
Figure 21. Voltage Change-Over Board
3Ø 240/139V Configuration
2. Connect the load wires to the UVWO terminals as
shown in Figure 22
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21.
2. Adjust voltage regulator knob (Figure 23) for an output
of 208V to obtain 120V at the UVWO terminals.
3. Connect the load wires to the UVWO terminals as
shown in Figure 25
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
120V
THREE-PHASE
240 VAC (LOAD CONNECTIONS)
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
Figure 22. UVWO Terminal Lugs
3Ø-240/1Ø-139 Connections
120V
120V
SINGLE-PHASE
120 VAC (LOAD CONNECTIONS)
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
Figure 25. UVWO Terminal Lugs 1Ø-120V
Connections
PAGE 32 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
OUTPUT TERMINAL PANEL CONNECTIONS
NOTICE
1Ø-480V UVWO Terminal Output Voltages
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exist that could cause a fire.
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
3Ø-480V UVWO Terminal Output Voltages
1. Jumper the voltage change-over board for 480V
operation as shown in Figure 26. 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.
2. Connect the load wires to the UVWO terminals as
shown in Figure 28.
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
480V
480V
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
480V
THREE-PHASE
480 VAC (LOAD CONNECTIONS)
Figure 28. UVWO Terminal Lugs 1Ø-480V
Connections
1Ø-277V UVWO Terminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
Figure 26. Voltage Change-Over Board
3Ø 480/277V Configuration
2. Connect the load wires to the UVWO terminals as
shown in Figure 27.
BLACK
RED
BLUE
WHITE
U
V
W
O
2. Connect the load wires to the UVWO terminals as
shown in Figure 29.
BLACK
RED
BLUE
WHITE
U
V
W
O
GREEN
GREEN
277V
277V
277V
THREE-PHASE
480 VAC (LOAD CONNECTIONS)
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
SINGLE-PHASE
277 VAC (LOAD CONNECTIONS)
GROUND
CONNECTION
MUST BE USED
AT ALL TIMES
Figure 29. UVWO Terminal Lugs 1Ø-277V
Connections
Figure 27. UVWO Terminal Lugs
3Ø-480V Connection
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 33
INSPECTION/SETUP
CIRCUIT BREAKERS
To protect the generator from an overload, a 3-pole, 600
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload. Three 50 amp
load circuit breakers have also been provided to protect
the auxiliary receptacles from overload. Make sure to itch
ALL circuit breakers to the OFF position prior to starting
the engine.
LUBRICATION OIL
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 30) on the dipstick. See Table 9 for
proper selection of engine oil.
FUEL CHECK
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
CAUTION
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 31). ALWAYS fill the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel
tanks beyond their capacities.
Figure 30. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the
oil drain plug, and refill with the specified amount of oil as
outlined in the John Deere Owner’s Manual. Oil should
be warm before draining.
Delo® engine oil is the recommended engine oil for this
generator. When replacing engine oil please refill using
Delo® 400 LE SAE 15W-40 (API CJ-4) engine oil.
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.
Generator Internal Fuel Tank
220
Table 9. Recommended Motor Oil
Trailer Fuel Tank
Figure 31. Internal Fuel Tank System
PAGE 34 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
INSPECTION/SETUP
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 32).
CAUTION
Figure 34. Full Fuel Tank
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 35).
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.
220
300
und
Gro
vel
Unle
Level Ground
=
DO NOT fill on
unlevel ground
!
!
nd
rou
G
vel
Unle
Level Ground
Figure 32. Only Fill on Level Ground
NOTICE
ONLY use #2 diesel fuel (ultra low sulfur diesel fuel)
when refueling.
Figure 35. Fuel Expansion
DEF Refueling
Diesel exhaust fluid is an aqueous solution made with 32.5%
high puirty urea (carbamide) and 67.5 deionized water.
DEF is used as a consumable in selective catalytic reduction
(SCR) in order to lower NOx concentration from diesel exhaust
emissions.
1. Remove the filler cap from the DEF tank (Figure 36),
2. Next add DEF fluid to the tank. DO NOT overfill.
2. Remove fuel cap and fill tank as shown in Figure 33.
DIESEL
FUEL
FUEL TANK
FILLER PORT
CAP
DE
FT
AN
K
Figure 33. Fueling the Generator
3. 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 34).
Figure 36. DEF Tank Filling
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 35
INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
John Deere recommends Cool-Gard II 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 John Deere Engine Owner’s Manual
for further details.
TM
WARNING
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 10 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
AIR CLEANER
Periodic cleaning/replacement is necessary. Inspect
air cleaner in accordance with the John Deere Engine
Owner’s Manual.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the John
Engine Owner’s Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 37) when depressed with the thumb as shown
below.
Table 10. Coolant Capacity
Engine and Radiator
10.3 gal (39 liters)
Reserve Tank
N/A
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 11) has been added.
Table 11. Anti-Freeze
Operating Temperatures
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
Figure 37. Fan Belt Tension
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
PAGE 36 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
INSPECTION/SETUP
BATTERY
When connecting battery do the following:
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.
1. NEVER connect the battery cables to the battery
terminals when the Auto-Off/Reset-Manual itch is in
either the AUTO or MANUAL position. ALWAYS make
sure that this itch is in the OFF/RESET position when
connecting the battery.
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.
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.
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 38) 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.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
NEGATIVE
POSITIVE
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.
CAUTION
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
ALTERNATOR
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the
circuit will be in short circuit instantaneously resulting the
alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
WIRING
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
PIPING AND HOSE CONNECTION
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check
hoses for leaks.
Figure 38. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 37
GENERATOR START-UP PROCEDURE (MANUAL)
BEFORE STARTING
STARTING (MANUAL)
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
1. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 39) in the OFF position prior to starting the
engine.
6. Place the Auto-Off/Reset Manual Switch in the
MANUAL position to start the engine (Figure 41).
Figure 41. Auto-Off/Reset Manual 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 placed in the Off/Reset position
before the engine can be restarted.
NOTICE
Engine will pre-heat automatically in cold weather
conditions." Glow Plug Hold " message will be displayed
and the engine will start automatically after pre-heating..
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 13. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
7. 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.
8. The generator’s frequency meter (Figure 42) should be
displaying the 60 cycle output frequency in HERTZ.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
5. Close all engine enclosure doors (Figure 40).
CORRECT
Figure 42. Frequency Meter
INCORRECT
Figure 40. Engine Enclosure Doors
PAGE 38 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR START-UP PROCEDURE (MANUAL)
9. The generator’s AC-voltmeter (Figure 43) will display
the generator’s output in VOLTS. If the voltage is not
within the specified tolerance,
140
180
220
°F
100
260
WATER TEMP
Figure 47. Coolant Temperature Gauge
Figure 43. Voltmeter
10. Use the voltage adjustment control knob (Figure 44)
to increase or decrease the desired voltage.
14. The tachometer gauge (Figure 48) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
120
150
180
60
0
RPMX10
210
SPEED
Figure 44. Voltage Adjust Control Knob
11. The ammeter (Figure 45) 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 45. Ammeter (No Load)
12. The engine oil pressure gauge (Figure 46) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 35 to 65
psi. (193~586 kPa).
25
0
50
Figure 48. Engine Tachometer Gauge
15. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 49).
Figure 49. Main, Aux. and GFCI
Circuit Breakers (ON)
16. Observe the generator’s ammeter (Figure 50) 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.
75
PSI
100
OIL PRESS
Figure 46. Oil Pressure Gauge
13. The coolant temperature gauge (Figure 47) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 185°~207°F (85°~97°C).
Figure 50. Ammeter (Load)
17. The generator will run until manually stopped or an
abnormal condition occurs.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 39
GENERATOR START-UP PROCEDURE (AUTO MODE)
STARTING (AUTO MODE)
DANGER
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to
the building’s electrical system may occur
without this transfer itch.
When starting generator in AUTO mode use the “Manual
Start-up” procedure except where noted (see below).
1. Perform steps 1 through 5 in the Before Starting section
as outlined in the Manual Starting Procedure.
2. Place the Auto Off/Reset Manual Switch (Figure 51)
in the AUTO position.
CAUTION
When connecting the generator to a isolation (transfer)
itch, 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.
Figure 51. Auto Off/Reset Manual Switch (AUTO)
3. Continue operating the generator as outlined in the
Manual Start-up procedure (start at step 7).
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.
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.
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 40 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR SHUT-DOWN PROCEDURES
EMERGENCY SHUTDOWN PROCEDURE
WARNING
NEVER stop the engine suddenly except in an
emergency.
1. Place the Auto Off/Reset Manual Switch (Figure 54)
in the OFF/RESET position.
NORMAL SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 52 to the OFF position.
AUTO
MANUAL
OFF/RESET
(CENTER)
Figure 54. Auto Off/Reset Manual Switch (OFF)
Figure 52. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
3. Place the Auto Off/Reset Manual Switch (Figure 53)
in the OFF/RESET position.
AUTO
MANUAL
OFF/RESET
(CENTER)
Figure 53. Auto Off/Reset Manual itch
(Off/Reset)
4. Verify that all status LEDs on the ECU control panel
are OFF (not lit).
5. Remove all loads from the generator.
6. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 41
MAINTENANCE
10 Hrs
DAILY
Table 12. Inspection/Maintenance
Check Engine Oil and Coolant Levels
X
Check Fuel Filter/Water Separator Bowl
X
Check Air Cleaner
X
Check Air Cleaner Element
X
Check for Leaks/Hoses/Clamps
X
Check for Loosening of Parts
500 Hrs
or Every
12 Months
3000 Hrs
or Every
36 Months
OTHER
X
Change Engine Oil and Oil Filter *
X
1
Clean Unit, Inside and Outside
Engine
250 Hrs
X
Replace Fuel Filter Elements
X
Check Engine Mounts
X
Service Battery
X
Check Air Intake Hoses
X
Check Fan Belt Condition
X
Check Automatic Belt Tensioner
X
Check Electrical Ground Connection
X
Clean Radiator, Check Cooling System
X
Coolant Solution Analysis, Add SCA's As Required
X
Pressure Test Cooling System
X
Check Engine Speed
X
Test Thermostats
X
Check and Adjust Engine Valve Clearance
X
Test Glow Plugs
X
Inspect Diesel Particulate Filter (DPF) *
X
2
Flush and Refill Cooling System*
2 yrs. or 2000 hrs.
3
Clean Inside of Fuel Tank
1000 hrs.
Clean DEF Tank
As Required
Check Crankcase Ventilation Filter*
1500 hrs.
4
Replace Air Cleaner Elements *
Generator
As Required
5
Measure Insulation Resistance Over 3M ohms
X
Check Rotor Rear Support Bearing
X
*1 During initial operation of a new engine, change oil and filter between a minimum of 100 hrs. and a maximum of 500 hrs. Service interval depends
on type of oil.
*2 Expectation for minimal service interval will be at least 4500 hrs. based on engine power. However, actual service should take place when
indicated by diagnostic gauge. Please contact nearest authorized Multiquip Service Center for DPF Cleaning.
*3 If John Deere COOL-GARD™ John Deere COOL-GARD™ II is used, the flushing intervals may be extended. See "Testing Diesel Coolant" in
engine manual.
*4 Minimal Service interval will be at least 1500 hrs. or when service indicator light turns on or as indicated by diagnostic guage. Critical emission
related service requred before 1500 hrs. is not necessary. The emissions-related warranty is valid up to 1500 hrs.
*5 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
PAGE 42 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MAINTENANCE
GENERAL INSPECTION
FUEL ADDITION
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)
Add diesel fuel (the grade may vary according to season
and locations).
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 55)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator (Figure 55) 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.
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel tank
for water contamination and drain the contents if required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
Cleaning Inside the Fuel Tank
Drain the fuel inside the fuel tank completely. Using a spray
washer (Figure 56) wash out any deposits or debris that
have accumulated inside the fuel tank.
Figure 55. Air Cleaner/Indicator
NOTICE
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused..
Figure 56. Fuel Tank Cleaning
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.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 43
MAINTENANCE
FUEL TANK INSPECTION
Replacing Oil Filter
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
„„Remove the old oil filter.
„„Rubber Suspension — Look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
„„Fuel Hoses — Inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
„„Apply a film of oil to the gasket/rubber seal (Figure 57)
on the new oil filter
OIL
FILTER
„„Fuel Tank Lining — Inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
„„Replace the fuel filter cartridge with new one every 500
hours or so.
„„Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
„„Vent any air
AIR REMOVAL
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel,
or after disassembling the fuel system, bleed the system
according to the following procedure. See the John Deere
Engine Manual for details.
To restart after running out of fuel, turn the itch to the “ON”
position for 15-30 seconds. Try again, if needed. This unit
is equipped with an automatic air bleeding system.
SEAL
Figure 57. Oil Filter
„„Install the new oil filter.
„„After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
„„Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
„„Check hoses for softening and kinks. Check clamps for
signs of leakage.
CHECK OIL LEVEL
„„Tighten both cocks and replace the overflow tank.
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 30.
„„Replace with coolant as recommended by the engine
manufacturer.
„„Close radiator cap tightly.
„„Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
PAGE 44 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MAINTENANCE
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
RADIATOR CLEANING
The radiator (Figure 58) 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.
JACKET WATER HEATER AND INTERNAL BATTERY
CHARGER 120 VAC INPUT RECEPTACLES
(OPTIONAL)
This generator can be optionally equipped with two 120
VAC, 20 amp input receptacles located on the output
terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 59). 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. Radiator Cleaning
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
„„Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
„„Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
„„Clean the entire generator, internal and external.
„„Cover the generating set and store in a clean, dry place.
„„Disconnect the battery.
Figure 59. Battery Charger and Jacket Water
Heater Power Connections
If the generator will be used daily, the battery should
normally not require charging. If the generator will be idle
(not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
power cord of adequate size.
„„Make sure engine coolant is at proper level.
NOTICE
„„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.
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger..
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 45
MAINTENANCE
EMISSION CONTROL
The emission control system employed with the John Deere
6068HFG09 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 62.
These devices help in filtering out large amounts of harmful
Nitrogen Oxides (NOx) and Particulate Matter (PM) which
are emitted by diesel engines. These exhaust emissions
pose serious environmental and health risks. It is important
to maintain and service this DOC/DPF emission safety
device on a periodic basis.
Diesel Oxidation Catalyst (DOC)
The DOC does not filter particles it oxidizes them. This
catalyst (honeycomb like structure) uses a chemical
process to break down pollutants in the exhaust stream
into less harmful components. In general this catalyst
collects/burns accumulated particulates. The DOC contains
palladium and platinum which serve as a catalysts to oxidize
hydrocarbons and carbon monoxide.
„„Forced (Stationary) Regeneration — A forced
regeneration only occurs when the operator has initiated
this action at the ECU and the ECM recognizes a preprogrammed set point of soot in the DPF to allow a forced
regeneration cycle.
This process can take anywhere from 30 minutes to
1-1/2 hours. When forced regeneration is in process all
loads must be removed from the generator, all circuit
breakers must be placed in the OFF position (OPEN),
and the engine speed set to idle.
DPF PRE-ALARM
In the event the Engine Control Unit (ECU) determines
the soot level back pressure and/or tempertaure has
reached a pre-determined trip point the ECU will indicate
a maintenance action is required by the operator.
This maintenance action will be shown on the LCD display
(DPF Warning Symbol) and the AMBER pre-alarm LED on
the ECU control panel will be ON (lit). See Figure 60.
ECU
Series 800 Controller
Diesel Particulate Filter (DPF)
Engine Started
DPF STAT
A diesel particulate filter (DPF) is a device designed to
remove diesel particulate matter (soot) from the exhaust
gas of a diesel engine. This type of filter usually removes
about 85-95% of the soot.
Soot accumulated in the DPF is removed via the
"regeneration process". Regeneration is the process
of removing the accumulated soot from the filter. This
regeneration process can occur in a few different ways.
„„Passive Regeneration — Occurs during normal
operation, typically under heavy load applications. Soot
is oxidized faster than it is collected.
„„Active Regeneration — Occurs when engine exhaust
temperatures are not high enough to oxidize the soot
collected in the DPF. Active regeneration requires
assistance from the engine to help increase the heat
level in the after-treatment system.
Active regeneration occurs at a normal engine speed
of 1800 rpm. In addition active regeneration is initiated
automatically by the Engine Control Module (ECM) timer
based program every 96 hours. This timer base program
will reset at the end of any regeneration mode.
Shutdown
Pre-Alarm
Alarm
Screen
Acknowledge Change
Option
Program
Exit
Figure 60. ECU DPF Pre-Alarm
The DPF pre-alarm status symbol displayed in Figure 60
indicates the soot level buildup has exceeded a predetermined level and a "Forced Regeneration" action is
required.
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.
PAGE 46 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MAINTENANCE
ECU
FORCED REGENERATION PROCEDURE
Follow the steps below to initiate a forced regeneration:
Series 800 Controller
Engine Started
DPF STAT
Shutdown
Pre-Alarm
1. Verify that the AMBER pre-alarm LED is ON or
FLASHING and the DPF symbol is shown on the
ECU display.
2. Place all circuit breakers in the OFF position.
3. Place the engine speed itch in the LOW position.
Alarm
Screen
Acknowledge Change
Option
Program
Exit
Figure 61. ECU DPF Engine Shutdown
NOTICE
If the RED engine shutdown LED is ever ON (Figure 61),
John Deere 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 John Deere Engine Service
Technician, using John Deere service software.
NOTICE
Soot and ash will accumulate in the DPF over time and
must be cleaned. The ash is a result of the normal oil
consumption while the engine is operated. The ash
cleaning interval will largely depend on the engine's
duty cycle and condition. Normal service intervals for
cleaning ash from the DPF is every 6 months (5000
hours).
4. Press the Program/Exit button on the ECU controller
and select FORCE REGEN mode.
5. Press and hold the request until the REGEN ACTIVE
message is displayed on the screen, then release.
6. Once activated, regeneration will start automatically
and the engine idling speed will increase through the
forced regeneration cycle. This process will last
anywhere from 30 minutes to 1-1/2 hours.
NOTICE
During the regeneration cycle the High
Exhaust System Temperature (HEST)
symbol may be displayed. Display of
this symbol can be considered normal
during the regeneration period.
ENGINE
EXHAUST (OUT)
DIESEL PARTICULATE
FILTER (DPF)
Figure 62. Typical DOC/DPF Unit
DIESEL OXIDATION
CATALYST (DOC)
ENGINE
EXHAUST (IN)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 47
MAINTENANCE
If the diesel exhaust fluid (DEF) symbol (Figure 63) is
displayed during ECU controller operation, it indicates the
following:
„„DEF tank level is below 10%. Reference Table 13, DEF
Level System Action System.
„„DEF quality is poor. The urea concentration to water is
to high or low.
„„Check DEF tank level and check active diagnostics
trouble codes (DTC).
ECU
Figure 64. DEF Tank Level Guage
If the engine emissions system malfunction (EESM)
symbol (Figure 65) is displayed during ECU controller
operation, it indicates the following:
„„Engine emissions are outside of normal operation range.
„„Sysyem fault has occured.
Series 800 Controller
Engine Started
DEF STAT
Shutdown
ECU
Pre-Alarm
Series 800 Controller
Engine Started
EESM
Shutdown
Pre-Alarm
Alarm
Screen
Acknowledge Change
Option
Program
Exit
Figure 63. ECU DEF State Pre-Alarm
Alarm
Screen
Acknowledge Change
NOTICE
Unit derate occurs at below 0% DEF level. If DEF level
is at empty, engine will shutdown. When refilling with
diesel fuel is required, refill DEF tank as well.
DIESEL ENGINE FLUID (DEF)
The amount of fluid in the DEF tank will be shown on the
ECU Controller main screen during operation. The symbol
shown in Figure 64 will be shown on the ECU monitor
indicating the level of fluid in the DEF tank.
DEF Level
Controller Message
—
Pre-Alarm Lamp
—
—
Shutdown Lamp
—
—
Program
Exit
Figure 65. Engine Emissions System
Malfunction Pre-Alarm
NOTICE
Generator derating occurs during soot levels 4 and 5.
Soot level 5 will cause the generator to shutdown If
this condition occurs contact your nearest authorized
service center.
Table 13. DEF Level System Action System
Over 10%
Below 10%
0%
—
DEF<10% Tank Level DEF<10% Tank Level
DEF Symbol
Option
Blinking
ON
ON
—
Empty or After 4 hrs. From 0%
DEF Tank Empty Level
Blinking
ON
ON
Engine Shutdown
PAGE 48 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MAINTENANCE
AUTO REGENERATION PROCEDURE
NOTICE
Auto regeneration process will automatically occur. No
operator action is required for this process. Allow the engine
to run for at least 30 minutes to complete the automatic
regeneration process.
DO NOT perform regeneration in conditions where it
may be unsafe due to high exhasust temperatures.
Reference Table 14 for the various soot level stages for
the DPF system.
The area above and around the generator during
the regeneration process should be free of any type
of debris, flammable or conbustible materials, as
temperatures during the regeneration process can
reach as high 1,022 °F (550 °C).
NOTICE
Generator derating occurs during soot levels 4 and 5.
Soot level 5 will cause the generator to shutdown If
this condition occurs contact your nearest authorized
service center.
Controller Message
DPF Condition
Pre-Alarm Lamp
Shutdown Lamp
NOTICE
Table 14. Automatic DPF System
Soot Level 0 Soot Level 1 & 2
Soot Level 3
FILTER CLEAN
N/A
N/A
REQUESTED
Regen Not
Moderate Soot
High Soot Level
Required
Level
N/A
N/A
N/A
N/A
REGENERATION (BASLER CONTROLLER)
When using the Basler DGC2020 HD controller
(Figure 66), the regeneration sequence is nearly identical
to the way the ECU835 controller works. The only difference
is that when a manual regen is needed it will announce a
pre-alarm on the controller. The pre-alarm will state “NEED
MAN REGEN” and “PRESS RUN BUTTON”.
Blinking
N/A
Soot Level 4
SOOT LEVEL
HIGH!
Very High Soot
Level
ON
N/A
Soot Level 5
SOOT LEVEL
VERY HIGH!
Service DPF
(Soot Only)
ON
ON
Engine
Shutdown
Press the “Alarm Silence” and the “Lamp Test” buttons at the
same time for 5 seconds. To exit the diagnostic mode you
can press reset, start the engine or turn control power off.
While in this condition, pressing the run button for 5 seconds
will initiate the Stationary Forced Regen, it will then display
a new pre-alarm “MAN REGEN ACTIVE”. Once the regen
completes, it will automatically shut down and display “MAN
REGEN COMPLT”.
DIAGNOSTIC MODE
There is a feature to put the controller in diagnostic mode.
Diagnostic mode will keep the key switch on for service tool
purposes. To place in diagnostic mode the engine must be
in the off mode.
Figure 66. Basler DGC2020 HD Controller
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 49
TRAILER MAINTENANCE
The following trailer maintenance guidelines are intended
to assist the operator in preventive maintenance.
TRAILER BRAKES
6. Replace the adjusting-hole cover.
7. Repeat the above procedure on all brakes.
8. Lower the trailer to the ground.
Properly functioning brake shoes and drums are essential
to ensure safety. The 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.
Check the fluid level in the master cylinder reservoir at least
every three months. If you tow your trailer an average of
1,000 miles per month in a hot and dry environment, you
must check the brake fluid level once a month. The brake
fluid reservoir is located on the tongue of the trailer. Always
fill with clean, uncontaminated DOT 4 brake fluid.
HYDRAULIC BRAKES
Figure 67 below displays the major hydraulic brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the “Manually Adjusting The
Brakes” section on this page. See Table 15 for Hydraulic
Brake Troubleshooting.
If your trailer has hydraulic brakes, they function the same
way the surge brakes do on your tow vehicle. The hydraulic
braking system must be inspected at least as often as the
brakes on the tow vehicle, but no less than once per year.
This inspection includes an assessment of the condition
and proper operation of the wheel cylinders, brake shoes,
brake drums and hubs.
MANUALLY ADJUSTING THE BRAKES
Most axles are fitted with a brake mechanism that will adjust
the brakes during a hard stop. However, some braking
systems are not automatically adjusted by hard stopping.
These brakes require manual adjustment. The following
steps apply to adjust most manually adjustable brakes.
1. Jack up the trailer and secure it on adequate capacity
jackstands.
2. Be sure the wheel and brake drum rotate freely.
3. Remove the adjusting-hole cover from the adjusting
slot on the bottom of the brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
starwheel of the adjuster assembly to expand the brake
shoes. Adjust the brake shoes out until the pressure
of the linings against the drum makes the wheel very
difficult to turn. Note: Your trailer maybe equipped with
drop spindle axles. See axle manual for your axle type.
You will need a modified adjusting tool for adjusting
the brakes in these axles. With drop spindle axles, a
modified adjusting tool with about an 80 degree angle
should be used.
Figure 67. Hydraulic Brake Components
HYDRAULIC BRAKE ACTUATOR
The hydraulic brake actuator (Figure 68) is the mechanism
that activates the trailer’s brake system. This actuator
changes fluid power into mechanical power. Therefore, the
fluid level must be checked frequently to assure that the
brakes function properly.
HYDRAULIC
BRAKE FLUID
RESERVOIR
5. Rotate the starwheel in the opposite direction until the
wheel turns freely with a slight drag.
Figure 68. Hydraulic Brake Actuator
PAGE 50 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
TRAILER MAINTENANCE
ADJUSTABLE
CHANNEL
WARNING
Failure to maintain proper fluid level in the actuator
may result in loss of braking action which could cause
severe property damage, injury or death.
Periodically check the actuator mounting fasteners for
damage or loosening. Inspect the actuator for worn or
damaged parts. As you are towing your trailer, be aware
of any changes in braking quality. This could be an early
warning of brake or actuator malfunction and requires
immediate attention. Consult a certified brake specialist to
make necessary adjustment or repairs.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Brake drums scored or
grooved?
Machine or replace.
Weak Brakes or
Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging
Brakes
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the
same axle?
Match tires.
Brake components loose,
bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness
incorrect or not adjusted
correctly?
Install new shoes and
linings.
Enough brake fluid or correct
fluid?
Replace rubber parts
fill with dot 4 fluid.
ADJUSTABLE CHANNEL
Your trailer may be equipped with an adjustable channel
(Figure 69) that allows the coupler to be raised or lowered
to a desired height. Periodically check the channel bolts
for damage or loosening.
NOTICE
When replacing channel mounting hardware (nuts,
bolts and washers), NEVER substitute substandard
hardware. Pay close attention to bolt length and grade.
ALWAYS use manufacturer's recommended parts
when replacing channel mounting hardware.
5/8" X 11" X 5"
BOLT
2" or 2-5/16" BALL
COUPLER
ADJUSTABLE
CHANNEL
5/8"
NYLOC
5/8" FLAT
NUT
WASHER
5/8" X 11" X 5"
BOLT
3" PINTLE EYE
RING
5/8" FLAT
WASHER
5/8"
NYLOC
NUT
Figure 69. Adjustable Channel
Wheel Bearings
Wheel bearings (Figure 70) must be inspected and
lubricated once a year or 12,000 miles to insure safe
operation of your trailer.
If trailer wheel bearings are immersed in water, they must
be replaced.
DANGER
If trailer wheels are under water for a long period of
time, wheel bearings may fail. If this is the case, service
wheel bearings immediately.
The possibility exists of the wheels falling off causing
equipment damage and severe bodily harm even death!
If the trailer has not been used for an extended amount
of time, have the bearings inspected and packed more
frequently, at least every six months and prior to use.
Follow the steps below to disassemble the wheel hub and
service the wheel bearings. See Figure 70.
BEARING
WHEEL
HUB
OIL
SEAL
BEARING COTTER
PIN
CUP
BEARING
BEARING
CUP
DUST
CAP
LUG
NUT
SPINDLE
WASHER
SPINDLE
NUT
Figure 70. Wheel Hub Components
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 51
TRAILER MAINTENANCE
„„After removing the dust cap, cotter pin, spindle nut and
spindle washer, remove the hub to inspect the bearings
for wear and damage.
„„Replace bearings that have flat spots on rollers, broken
roller cages, rust or pitting. Always replace bearings
and cups in sets. The inner and outer bearings are to
be replaced at the same time.
DANGER
Improper weld repair will lead to early failure of the
trailer structure and can cause serious injury or death.
DO NOT repair cracked or broken welds unless you
have a certified welder perform the repair. If not, have
the welds repaired by your dealer.
„„Replace seals that have nicks, tears or wear.
„„Lubricate the bearings with a high quality EP-2
automotive wheel bearing grease.
WHEEL HUB ADJUSTMENT
Every time the wheel hub is removed and the bearings are
reassembled, follow the steps below to check the wheel
bearings for free running and adjust.
„„Turn the hub slowly, by hand, while tightening the spindle
nut until you can no longer turn the hub by hand.
„„Loosen the spindle nut just until you are able to turn it
(the spindle nut) by hand. Do not turn the hub while the
spindle nut is loose.
WARNING
If the trailer is involved in an accident, have it inspected
immediately by qualified personnel. In addition, the
trailer should be inspected annually for signs of wear
or deformations.
LEAF SUSPENSION
The leaf suspension springs and associated components
(Figure 71) 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.
SHACKLE SUPPORT
IS WELDED
HANGER SUPPORT
TO FRAME
IS WELDED
TO FRAME
HANGER
SUPPORT
SHACKLE
NUT
NUT
„„Install a new cotter pin through the spindle nut and axle.
„„Check the adjustments. Both the hub and the spindle nut
should be able to move freely (the spindle nut motion
will be limited by the cotter pin).
DANGER
NEVER crawl under the trailer unless it is on firm
and level ground and resting on properly placed and
secured jackstands.
The possibility exists of the trailer falling thus causing
equipment damage and severe bodily harm even death!
DANGER
When performing trailer inspection and maintenance
activities, you must jack up the trailer using jacks and
jackstands.
When jacking and using jackstands, place them so
as to clear wiring, brake lines, and suspension parts
(i.e., springs, torsion bars). Place jacks and jackstands
inside of the perimeter strip on the supporting structure
to which the axles are attached.
TIE
PLATE
AXLE
SHACKLE
BOLT
HANGER
SUPPORT
BOLT
U-BOLT
LOCKING
NUT
Figure 71. Leaf Suspension Components
DANGER
Worn or broken suspension parts can cause loss of
control, damage to equipment and severe bodily injury,
even death!
Check suspension regularly.
PAGE 52 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
TRAILER MAINTENANCE
Torque suspension components (Figure 71) as referenced
in Table 16.
Table 17. Tire Wear Troubleshooting
Wear Pattern
Table 16. Suspension Torque Requirements
Cause
Solution
Center Wear
Over inflation.
Adjust pressure to particular
load per tire manufacturer.
Edge Wear
Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Item
Torque (Ft.-Lbs.)
3/8" U-Bolt
Min-30 Max-35
7/16" U-Bolt
Min-45 Max-60
1/2" U-Bolt
Min-45 Max-60
Side Wear
Loss of camber
or overloading.
Shackle Bolt
Snug fit only. Parts must rotate freely.
Locking nuts or cotter pins are
provided to retain nut-bolt assembly.
Make sure load does not
exceed axle rating.
Align wheels.
Toe Wear
Incorrect toe-in.
Align wheels.
Cupping
Out-of-balance.
Check bearing adjustment
and balance tires.
Wheel lockup and
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Spring Eye Bolt
Shoulder Type
Shackle Bolt
Min-30 Max-50
TIRES/WHEELS/LUG NUTS
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing
the trailer wheels it is important the wheels, tires, and axle
are properly matched.
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.
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 17 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Flat Spots
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 71). DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 53
TRAILER MAINTENANCE
Figure 72. Wheel Lug Nuts
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
PAGE 54 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
TRAILER WIRING DIAGRAM
Figure 73. Trailer/Towing Vehicle Wiring Diagram
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 55
GENERATOR WIRING DIAGRAM
CONTROL BOX
X
Y
COT. B
COT. B
U2
U1
V2
V1
W2
W1
X
U2
Y
Z
Z
O
1 2
CN2
CN3
CN4
U1
V2
V1
W2
W1
O
Voltage Change-Over
Board-240V Set
CN1
CONTROL PANEL
Voltage Change-Over
Board-480V Set
3
A J C
B K D
1 2
3
4
k P1 P2
1 2
3
3
CONTROL
BOX
SIDE
1 2
U V W
1 2
13
AVR CONNECTOR
(VIEW FROM INSERTING
WIRE SIDE)
1 2
CB1 CONNECTOR
(VIEW FROM INSERTING
WIRE SIDE)
1
SYMBOL
3 2
1
T1 S1 R1
3
U1 V1 W1
1 2
CONTROL U2 1
PANEL W2 3
SIDE
3
R1 S1 T1
CONNECTOR
(VIEW FROM INSERTING
WIRE SIDE)
C1C2
2 1
CIRCUIT
BREAKER C2 C1
SIDE
2
W1 V1 U1
1 U2
3 W2
COLOR CODE
B
L
BR
G
GR
V
P
WIRE COLOR
BLACK
BLUE
BROWN
GREEN
GRAY
VIOLET
PINK
R
W
Y
LB
LG
O
Ar
Fg
Ex Ar
Ex Fg
AVR
DESIGNATION
ARMATURE WINDING
MAIN GENERATOR FIELD WINDING
EXCITER ARMATURE WINDING
EXCITER FIELD WINDING
AUTOMATIC VOLTAGE REGULATOR
VS
~V
DESIGNATION
VOLTAGE CHANGE-OVER BOARD
AMMETER CHANGE-OVER SWITCH
AC AMMETER 0~750, 1,500A
VOLTMETER CHANGE-OVER SWITCH
AC VOLTMETER 0~600V
FREQUENCY METER 45~65 Hz
RECTIFIER
CB2~3
AUX. CIRCUIT BREAKER 20A
CURRENT TRANSFORMER 750/5A
CB4~6
AUX. CIRCUIT BREAKER 50A
VOLTAGE REGULATING RHEOSTAT
Re
CB1
OC
COT. B
AS
A
~
F
VR
CT1~3
SYMBOL
CIRCUIT BREAKER 600 AMPS
CON2~3 RECEPTACLE 520R GFCI 20A, 125V
OVER CURRENT RELAY
CON3~5 RECEPTACLE CS-6369 50A, 120/240V
WIRE COLOR
RED
WHITE
YELLOW
LIGHT BLUE
LIGHT GREEN
ORANGE
PAGE 56 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR WIRING DIAGRAM, BASLER (OPTION)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 57
ENGINE WIRING DIAGRAM (ECU 835)
PAGE 58 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENGINE WIRING DIAGRAM (BASLER DGC2020HD OPTION)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 59
BATTERY CHARGER WIRING DIAGRAM (OPTION)
PAGE 60 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
WATER HEATING ELEMENT WIRING DIAGRAM (OPTION)
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 61
TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Symptom
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
Table 19. Generator Troubleshooting
Possible Problem
Solution
AC Voltmeter defective?
Check output voltage using a voltmeter.
Is wiring connection loose?
Check wiring and repair.
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Check for approximately 19 ohms across J & K on CN1
Is engine speed correct?
Turn engine throttle lever to “High”.
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?
Check load and repair.
Over current?
Confirm load requirements and reduce.
Defective circuit breaker?
Check and replace.
Over current Relay actuated? Confirm load requirement and replace.
PAGE 62 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
TROUBLESHOOTING DIAGNOSTICS
The engine controller of this generator diagnoses problems
that arise from the engine control system and the engine
itself.
1. With the engine stopped (OFF). Push and hold the
Hour Check Button (Figure 74) located on the control
panel.
HOUR CHECK
BUTTON
5. Push the Program/Exit Button on the ECU controller
and select the Fault Diagnostics mode. This mode
enables the ability to carry out the fault diagnostics
as listed below:
„„DM1 Active Faults — Displays active fault messages
and codes.
„„DM2 Messages and Codes — Displays messages and
codes which previously occurred that are recorded in the
Engine Control Module (ECM).
„„Last Shutdown — Displays the messages and codes
that caused the most recent shutdown.
6. After perfoming diagnostic tests, place the Auto Off/
Reset Manual Switch in the OFF position
Figure 74. Hour Check Button
2. While keeping the Hour Check Button pressed, place
the Auto Off/Reset Manual Switch (Figure 75) in the
MANUAL position.
Figure 75. 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.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 63
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Touch Screen Operation
DGC-2020HDs with the color touch screen display option (style xTxxxxxxx) provide a convenient means
of navigating through menus and settings by allowing direct interaction with what is displayed. All
operations that can be performed using the touch screen can also be performed using the pushbuttons.
However, critical settings must be initiated using the pushbuttons to prevent accidental operation with the
touch screen.
Touch screen controls are illustrated in Figure A. Lettered locators in Figure A correspond to the control
descriptions of Table A.
Figure A. Touch Screen Controls
Table A. Touch Screen Control Descriptions
Locator
Description
A
Enter button. This button, found only on the overview screen, enters the Main Menu.
B
Breaker control. To send an open or close request to a breaker in the system, follow these
steps:
1. Touch the corresponding breaker in the diagram.
2. Press the up or down arrow keys to scroll the options.
3. Press Edit to send the selected breaker command request.
C
Generator metering. Touch the generator in the diagram to view metered voltage, current,
frequency, kW, kvar, and power factor values of the local generator.
PAGE 64 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Locator
Description
D
Bus metering. Touch a bus in the diagram to view metered voltage, current, frequency, kW,
kvar, and power factor values of the corresponding bus in the system.
E
Mains metering. Touch the mains in the diagram to view metered voltage, current,
frequency, kW, kvar, and power factor values of the mains bus.
F
Back button. Touch the Back button to return to the previous menu.
G
Menu Option. Touch a menu option to enter its submenu. If the option is an editable value,
adjust it using the arrow pushbuttons, and press the Edit pushbutton to accept the change.
H
Up and Down Arrows. Touching the Up arrow scrolls the menu options toward the top of the
list and touching the Down arrow scrolls the menu options toward the bottom of the list.
I
Scroll box. This represents the range of options in the list that are currently being displayed.
The scroll box has no touch commands.
J
Scroll bar. Scroll bars represent the entire list of options for the current menu screen.
Touching a point in the white portion of the scroll bar will display the menu options at that
position in the list.
Disabling the Touch Screen
Touch screen controls may be disabled by way of a setting, front panel pushbuttons, or automatically. A
setting is provided on the Front Panel HMI screen to enable or disable the touch screen control. For
details, refer to Display Setup, below. To disable touch screen controls using the front panel pushbuttons,
press and hold Lamp Test then press Edit. Touch screen controls are disabled automatically if the touch
screen detects a press for longer than 60 seconds.
Programmable Indicator Configuration
Up to three LED indicators may be programmed to suit the needs of a particular application. A
replaceable card (Figure B) is provided that can be labeled to match the function of each programmable
indicator.
Figure B. Programmable Indicator Label Card
Information about configuring DGC-2020HD logic to control the programmable indicators can be found in
the BESTlogic™Plus chapter.
To label the programmable indicators, perform the following steps.
1. Print the label text on readily-available address label sheets. The label card accommodates
adhesive-backed labels measuring 0.5 by 1.75 inches. Avery part number 18167 is suitable for
this purpose.
2. Remove all control power from the DGC-2020HD.
3. Remove the fasteners from the four mounting studs on the DGC-2020HD and separate it from the
mounting panel or optional escutcheon plate. Disconnect the nine terminal block connectors; the
Start, Run, and Pre relays; and the Ethernet (copper or fiber), USB, and DB-9 connectors.
4. Lay the front panel face-down on a suitable work surface.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 65
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
5. Grasp the tab of the label card and pull free. The label card tab is located on the rear of the DGC2020HD, see Figure C. When facing the back of the panel, the label card tab is on the left.
6. Apply the labels created in step 1 to the label cards. The rectangle outlines on the label card
serve as guides for attaching the labels.
7. After applying the new labels, insert the label card into the slot. Ensure that the label card is
oriented properly by viewing the custom labels through the label windows of the front panel.
8. Move the DGC-2020HD adjacent to the mounting panel or optional escutcheon plate and
reconnect the cables removed in step 3.
9. Secure the DGC-2020HD to the mounting panel or optional escutcheon plate with the fasteners
removed in step 3. The torque applied to the mounting hardware should not exceed 20 inchpounds or 2.2 newton meters.
10. If desired, verify the function of the programmed indicators before returning the DGC-2020HD to
service.
Figure C. Label Card Slot Location
Display Operation and Navigation
The front panel display is used to locally make settings changes and display metering values. Refer to
items 11, 12 and 13 in Figure 6 for information on changing settings through the front panel and
navigating through the screens.
PAGE 66 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Login and Permissions
When attempting to change a protected setting, the DGC-2020HD displays the Login Required screen. To
log in, use the up or down arrow keys to scroll through the characters. Use the left or right arrow keys to
enter more characters. Once the user name and password have been entered, press the Edit key to log
in. To log out, press the Reset key while viewing any screen other than the following screen types:
• Action Event Screen (alarm/pre-alarm screens)
• CSV Screen
• Edit Screen
• Pixel Test Screen
• Real Time Clock Screen
• Overview Screen
If communication access is active through the modem, USB port, or Ethernet port, the front panel displays
®
“REMOTE COMMS”. If the remote user is logged in to BESTCOMSPlus with Control security access or
higher, the front panel can only be used for viewing metering data and settings information. Remote
security access must be ended before modifying settings through the front panel.
Changing a Setting
To change a setting, navigate to the setting and press the Edit key. If you are not already logged in, you
will be prompted for your password. Use the up or down arrow keys to raise or lower the value. Use the
right or left arrow keys to select different digits. Press the Edit key again when finished.
Sleep Mode
Sleep mode de-energizes the LCD backlight when no pushbutton activity is detected for the duration of
the LCD Backlight Timeout delay. Front panel LEDs remain lit during sleep mode. In units with the default
monochrome LCD, the LCD heater is turned off during sleep mode. To enter sleep mode, the DGC2020HD must be operating in OFF mode or Auto mode with the engine not running. Normal display
operation resumes when any pushbutton is pressed or the genset is started remotely via the ATS input.
Sleep mode is not entered while an alarm is active. Sleep mode can be permanently disabled through
®
BESTCOMSPlus or the front panel.
Overview Screen
The overview screen is the uppermost screen in the menu structure and is displayed by default. It
displays metering information as well as a one-line diagram of the system’s breaker configuration.
System Configuration One-Line Diagram
A one-line diagram of the system breaker configuration is displayed on the front panel. This diagram
changes in real time to reflect the current state of the breakers.
The one-line diagram appears on both the front panel Overview and Summary screens.
Figure D, illustrates the different configurations of the one-line diagram.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 67
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
A
B
G
B
A
G
C
Generator Breaker and Tie Breaker
Tie Breaker
SYS
GG
Generator Breaker, Group Breaker, and Mains Breaker
L
GG
L
GG
G
Generator Breaker and Group Breaker
Generator Breaker and Mains Breakers
L
G
L
G
Generator Breaker, Group Breaker, and System Bus
Generator Breaker and System Bus
SYS
G
P0071-90
Tie Breaker and Tie Breaker
B
G
G
C
L
Generator Breaker
None
Figure D. System Configuration One-Line Diagrams
The diagrams in Figure D show all breakers in the open position and all buses in a dead/unstable state.
Breaker and bus states in the diagram change in real time to reflect the actual breaker and bus status.
When a breaker is open, the line between the contacts is vertical and when the breaker is closed, the line
is horizontal. A stable bus is indicated by a filled rectangle and a bus in any state other than stable is
indicated by an unfilled rectangle. On the optional touch screen, a dead bus is indicated by a green
colored line segment and an energized (failed or stable) is indicated by a red colored line segment. See
Figure E for the different breaker and bus states.
PAGE 68 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Both buses dead/unstable
One bus stable and the other dead/unstable
Both buses stable
Breaker Closed
Breaker Open and OK to Close
Breaker Open and Not OK to Close
Breaker Open and Close Request Sent
Breaker Closed and Open Request Sent
!
!
Breaker Open and Failed to Close
Breaker Closed and Failed to Open
P0071-91
Figure E . One-Line Diagram Breaker and Bus States
Front Panel Shortcuts
Front panel shortcuts allow the user to intuitively view metered bus values and issue breaker commands
by simply selecting components in the one-line diagram.
While viewing the overview screen, press Edit to enable a cursor in the system configuration one-line
diagram. Moving the cursor, by using the left and right arrow keys, selects different components in the
system diagram. A component selected by the cursor is displayed with inverted colors to differentiate it
from the rest.
Select a bus in the diagram with the cursor and press Edit to view metered voltage, current, frequency,
kW, kvar, and power factor values of the corresponding bus in the system.
To send an open or close request to a breaker in the system, move the cursor to the corresponding
breaker in the diagram and press Edit. Press the up or down arrow keys to scroll the options. Press Edit
again to send the selected breaker command request.
The system configuration one-line diagram which is displayed on the overview screen is determined by
the System Type setting selection. For details on configuring the system type, see the Configuration
chapter.
Scrolled Metering
®
BESTCOMSPlus Navigation Path: Settings Explorer, General Settings, Front Panel HMI
Front Panel Navigation Path: Settings > General Settings > Front Panel HMI
When scrolled metering is enabled, user-selected metering values are displayed on the overview screen.
Any number of the available values can be displayed. Up to nine values are displayed on the screen at
one time. After the scroll time delay has elapsed, the next set of values is displayed and so on.
When scrolled metering is disabled, only the following parameters are displayed on the overview screen:
• VOLT∗
• AMP∗
• PH∗
• Hz
• OIL
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 69
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
•
•
•
FUEL/DEF†
TEMP/RUN HRS
BATT/RUN HRS
∗ When scrolled metering is disabled, individual phase information can be automatically toggled at a rate
set by the Phase Toggle Delay setting on the Front Panel HMI screen. When the Phase Toggle Delay is
set to zero, information for each phase is obtained by pressing the up or down arrow keys on the front
panel. When it is set to a number other than zero, the display will toggle through the phases automatically
at the rate specified by the Phase Toggle Delay Setting. The overview screen automatically alternates the
display of TEMP/BATT and RUN HRS.
† When a Selective Catalytic Reduction (SCR) with Diesel Exhaust Fluid (DEF) exhaust after-treatment
system is implemented, the overview screen automatically alternates the display of FUEL level and DEF
level.
To select the scrolling values, navigate to the Settings, General Settings, Front Panel HMI screen and edit
the Scrolled Item Selection. The following parameters may be placed in the scrolling overview:
Adjusted Reserve Available
Analog Expansion Module 1: Inputs: AEM1 In1
Analog Expansion Module 1: Inputs: AEM1 In2
Analog Expansion Module 1: Inputs: AEM1 In3
Analog Expansion Module 1: Inputs: AEM1 In4
Analog Expansion Module 1: Inputs: AEM1 In5
Analog Expansion Module 1: Inputs: AEM1 In6
Analog Expansion Module 1: Inputs: AEM1 In7
Analog Expansion Module 1: Inputs: AEM1 In8
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD1
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD2
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD3
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD4
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD5
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD6
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD7
Analog Expansion Module 1: Resistance
Temperature Detectors (RTD): AEM1 RTD8
Analog Expansion Module 1: Thermocouples:
AEM1 TC1
Analog Expansion Module 1: Thermocouples:
AEM1 TC2
Analog Expansion Module 2: Inputs: AEM2 In1
Analog Expansion Module 2: Inputs: AEM2 In2
Analog Expansion Module 2: Inputs: AEM2 In3
Analog Expansion Module 2: Inputs: AEM2 In4
Analog Expansion Module 2: Inputs: AEM2 In5
Analog Expansion Module 2: Inputs: AEM2 In6
Analog Expansion Module 2: Inputs: AEM2 In7
Analog Expansion Module 2: Inputs: AEM2 In8
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD1
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD2
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD3
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD4
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD5
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD6
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD7
Analog Expansion Module 2: Resistance
Temperature Detectors (RTD): AEM2 RTD8
Analog Expansion Module 2: Thermocouples:
AEM2 TC1
Analog Expansion Module 2: Thermocouples:
AEM2 TC2
Analog Expansion Module 3: Inputs: AEM3 In1
Analog Expansion Module 3: Inputs: AEM3 In2
Analog Expansion Module 3: Inputs: AEM3 In3
Analog Expansion Module 3: Inputs: AEM3 In4
Analog Expansion Module 3: Inputs: AEM3 In5
Analog Expansion Module 3: Inputs: AEM3 In6
Analog Expansion Module 3: Inputs: AEM3 In7
Analog Expansion Module 3: Inputs: AEM3 In8
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD1
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD2
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD3
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD4
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD5
PAGE 70 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD6
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD7
Analog Expansion Module 3: Resistance
Temperature Detectors (RTD): AEM3 RTD8
Analog Expansion Module 3: Thermocouples:
AEM3 TC1
Analog Expansion Module 3: Thermocouples:
AEM3 TC2
Analog Expansion Module 4: Inputs: AEM4 In1
Analog Expansion Module 4: Inputs: AEM4 In2
Analog Expansion Module 4: Inputs: AEM4 In3
Analog Expansion Module 4: Inputs: AEM4 In4
Analog Expansion Module 4: Inputs: AEM4 In5
Analog Expansion Module 4: Inputs: AEM4 In6
Analog Expansion Module 4: Inputs: AEM4 In7
Analog Expansion Module 4: Inputs: AEM4 In8
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD1
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD2
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD3
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD4
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD5
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD6
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD7
Analog Expansion Module 4: Resistance
Temperature Detectors (RTD): AEM4 RTD8
Analog Expansion Module 4: Thermocouples:
AEM4 TC1
Analog Expansion Module 4: Thermocouples:
AEM4 TC2
Analog Inputs: Analog In 1
Analog Inputs: Analog In 2
Analog Inputs: Analog In 3
Analog Inputs: Analog In 4
Analog Outputs: AVR Output
Analog Outputs: GOV Output
Analog Outputs: LS Output
Base Load Level
Battery Voltage
Boost Pressure
Bus 1 Current: 3i0
Bus 1 Current: Average
Bus 1 Current: I1
Bus 1 Current: I2
Bus 1 Current: Phase A Current
Bus 1 Current: Phase B Current
Bus 1 Current: Phase C Current
Bus 1 Current: Ground
Bus 1 Dead
Bus 1 Failed
Bus 1 Forward Rotation
Bus 1 Frequency: Frequency
Bus 1 Frequency: Max ROCOF
Bus 1 Frequency: ROCOF
Bus 1 Power: Max Vector Shift
Bus 1 Power: Negative Var Hours Total
Bus 1 Power: Negative Watt Hours Total
Bus 1 Power: Phase A Complex Power
Bus 1 Power: Phase A Power Factor
Bus 1 Power: Phase A Vars
Bus 1 Power: Phase A Watts
Bus 1 Power: Phase B Complex Power
Bus 1 Power: Phase B Power Factor
Bus 1 Power: Phase B Vars
Bus 1 Power: Phase B Watts
Bus 1 Power: Phase C Complex Power
Bus 1 Power: Phase C Power Factor
Bus 1 Power: Phase C Vars
Bus 1 Power: Phase C Watts
Bus 1 Power: Positive Var Hours Total
Bus 1 Power: Positive Watt Hours Total
Bus 1 Power: Power Factor Lead/Lag
Bus 1 Power: Total Complex Power
Bus 1 Power: Total Power Factor
Bus 1 Power: Total Vars
Bus 1 Power: Total Watts
Bus 1 Power: Volt-Ampere Hours Total
Bus 1 Reverse Rotation
Bus 1 Stable
Bus 1 Voltage: Average Voltage L-L
Bus 1 Voltage: Average Voltage L-N
Bus 1 Voltage: Connection
Bus 1 Voltage: V2
Bus 1 Voltage: Voltage Phase A
Bus 1 Voltage: Voltage Phase A To Phase B
Bus 1 Voltage: Voltage Phase B
Bus 1 Voltage: Voltage Phase B To Phase C
Bus 1 Voltage: Voltage Phase C
Bus 1 Voltage: Voltage Phase C To Phase A
Bus 2 Current: 3i0
Bus 2 Current: Average
Bus 2 Current: I1
Bus 2 Current: I2
Bus 2 Current: Phase A Current
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 71
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Bus 2 Current: Phase B Current
Bus 2 Current: Phase C Current
Bus 2 Current: Ground
Bus 2 Dead
Bus 2 Failed
Bus 2 Forward Rotation
Bus 2 Frequency: Frequency
Bus 2 Frequency: Max ROCOF
Bus 2 Frequency: ROCOF
Bus 2 Power: Max Vector Shift
Bus 2 Power: Negative Var Hours Total
Bus 2 Power: Negative Watt Hours Total
Bus 2 Power: Phase A Complex Power
Bus 2 Power: Phase A Power Factor
Bus 2 Power: Phase A Vars
Bus 2 Power: Phase A Watts
Bus 2 Power: Phase B Complex Power
Bus 2 Power: Phase B Power Factor
Bus 2 Power: Phase B Vars
Bus 2 Power: Phase B Watts
Bus 2 Power: Phase C Complex Power
Bus 2 Power: Phase C Power Factor
Bus 2 Power: Phase C Vars
Bus 2 Power: Phase C Watts
Bus 2 Power: Positive Var Hours Total
Bus 2 Power: Positive Watt Hours Total
Bus 2 Power: Power Factor Lead/Lag
Bus 2 Power: Total Complex Power
Bus 2 Power: Total Power Factor
Bus 2 Power: Total Vars
Bus 2 Power: Total Watts
Bus 2 Power: Volt-Ampere Hours Total
Bus 2 Reverse Rotation
Bus 2 Stable
Bus 2 Voltage: Average Voltage L-L
Bus 2 Voltage: Average Voltage L-N
Bus 2 Voltage: Connection
Bus 2 Voltage: V2
Bus 2 Voltage: Voltage Phase A
Bus 2 Voltage: Voltage Phase A To Phase B
Bus 2 Voltage: Voltage Phase B
Bus 2 Voltage: Voltage Phase B To Phase C
Bus 2 Voltage: Voltage Phase C
Bus 2 Voltage: Voltage Phase C To Phase A
Charge Air Temperature
Contact Expansion Module 1: CEM1 Input 1
Contact Expansion Module 1: CEM1 Input 2
Contact Expansion Module 1: CEM1 Input 3
Contact Expansion Module 1: CEM1 Input 4
Contact Expansion Module 1: CEM1 Input 5
Contact Expansion Module 1: CEM1 Input 6
Contact Expansion Module 1: CEM1 Input 7
Contact Expansion Module 1: CEM1 Input 8
Contact Expansion Module 1: CEM1 Input 9
Contact Expansion Module 1: CEM1 Input 10
Contact Expansion Module 2: CEM2 Input 1
Contact Expansion Module 2: CEM2 Input 2
Contact Expansion Module 2: CEM2 Input 3
Contact Expansion Module 2: CEM2 Input 4
Contact Expansion Module 2: CEM2 Input 5
Contact Expansion Module 2: CEM2 Input 6
Contact Expansion Module 2: CEM2 Input 7
Contact Expansion Module 2: CEM2 Input 8
Contact Expansion Module 2: CEM2 Input 9
Contact Expansion Module 2: CEM2 Input 10
Contact Expansion Module 3: CEM3 Input 1
Contact Expansion Module 3: CEM3 Input 2
Contact Expansion Module 3: CEM3 Input 3
Contact Expansion Module 3: CEM3 Input 4
Contact Expansion Module 3: CEM3 Input 5
Contact Expansion Module 3: CEM3 Input 6
Contact Expansion Module 3: CEM3 Input 7
Contact Expansion Module 3: CEM3 Input 8
Contact Expansion Module 3: CEM3 Input 9
Contact Expansion Module 3: CEM3 Input 10
Contact Expansion Module 4: CEM4 Input 1
Contact Expansion Module 4: CEM4 Input 2
Contact Expansion Module 4: CEM4 Input 3
Contact Expansion Module 4: CEM4 Input 4
Contact Expansion Module 4: CEM4 Input 5
Contact Expansion Module 4: CEM4 Input 6
Contact Expansion Module 4: CEM4 Input 7
Contact Expansion Module 4: CEM4 Input 8
Contact Expansion Module 4: CEM4 Input 9
Contact Expansion Module 4: CEM4 Input 10
Contact Inputs: Input 1
Contact Inputs: Input 2
Contact Inputs: Input 3
Contact Inputs: Input 4
Contact Inputs: Input 5
Contact Inputs: Input 6
Contact Inputs: Input 7
Contact Inputs: Input 8
Contact Inputs: Input 9
Contact Inputs: Input 10
Contact Inputs: Input 11
Contact Inputs: Input 12
Contact Inputs: Input 13
Contact Inputs: Input 14
Contact Inputs: Input 15
PAGE 72 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Contact Inputs: Input 16
Contact Outputs: Output 1
Contact Outputs: Output 2
Contact Outputs: Output 3
Contact Outputs: Output 4
Contact Outputs: Output 5
Contact Outputs: Output 6
Contact Outputs: Output 7
Contact Outputs: Output 8
Contact Outputs: Output 9
Contact Outputs: Output 10
Contact Outputs: Output 11
Contact Outputs: Output 12
Contact Outputs: Prestart
Contact Outputs: Run
Contact Outputs: Start
Coolant Level Settings
Coolant Pressure
Coolant Temperature
Device ID
Diesel Exhaust Fuel Tank Level 1
Diesel Exhaust Fuel Tank Level 2
Differential: Iop 2nd A
Differential: Iop 2nd B
Differential: Iop 2nd C
Differential: Iop 5th A
Differential: Iop 5th B
Differential: Iop 5th C
Differential: Iop A
Differential: Iop B
Differential: Iop C
Differential: Iop N
Differential: Ir A
Differential: Ir B
Differential: Ir C
DPF Outlet Gas Temperature
Engine Intercooler Temperature
Engine Load
Engine Oil Temperature
Engine Percent Load
Engine Speed (Rpm)
Fuel Level
Fuel Pressure
Fuel Rate
Fuel Temperature
Gen Current: 3i0
Gen Current: Average
Gen Current: Ground Current
Gen Current: I1
Gen Current: I2
Gen Current: Phase A Current
Gen Current: Phase B Current
Gen Current: Phase C Current
Gen Current: Ground
Gen Dead
Gen Failed
Gen Forward Rotation
Gen Frequency: Frequency
Gen Frequency: Max ROCOF
Gen Frequency: ROCOF
Gen Power: Max Vector Shift
Gen Power: Negative Var Hours Total
Gen Power: Negative Watt Hours Total
Gen Power: Phase A Complex Power
Gen Power: Phase A Power Factor
Gen Power: Phase A Vars
Gen Power: Phase A Watts
Gen Power: Phase B Complex Power
Gen Power: Phase B Power Factor
Gen Power: Phase B Vars
Gen Power: Phase B Watts
Gen Power: Phase C Complex Power
Gen Power: Phase C Power Factor
Gen Power: Phase C Vars
Gen Power: Phase C Watts
Gen Power: Positive Var Hours Total
Gen Power: Positive Watt Hours Total
Gen Power: Power Factor Lead/Lag
Gen Power: Total Complex Power
Gen Power: Total Power Factor
Gen Power: Total Vars
Gen Power: Total Watts
Gen Power: Volt-Ampere Hours Total
Gen Reverse Rotation
Gen Stable
Gen Voltage: Average Voltage L-L
Gen Voltage: Average Voltage L-N
Gen Voltage: Connection
Gen Voltage: V2
Gen Voltage: Voltage Phase A
Gen Voltage: Voltage Phase A To Phase B
Gen Voltage: Voltage Phase B
Gen Voltage: Voltage Phase B To Phase C
Gen Voltage: Voltage Phase C
Gen Voltage: Voltage Phase C To Phase A
Generated kvar
Generated kW
Injector Metering Rail Pressure
Intake Manifold Temperature
kvar Error
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 73
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
kvar PID
kvar Ramp Status
kvar Setpoint
kW Error
kW Load Percent
kW PID
kW Ramp Status
Load Share Active
Logic Control Relays: LCR 1-64
LS Input
Mains Base Load
Mains Total System kW Load
Next To Start
Next To Stop
Number of Units
Number of Units in Active Segment
Number of Units Online
Oil Pressure
PF Mode
PF Setpoint
Ramped Var Demand
Ramped Watt Demand
Rated kvar
Rated kW
Real Time Clock: Date
Real Time Clock: Time
Reserve Available
Speed Bias Output
Speed Error
Speed PID
Speed Source
System Load Bus: Frequency
System Load Bus: Total PF
System Load Bus: Total var
System Load Bus: Total Watt
System Load Bus: Average Current
System Load Bus: Average Voltage
System Generated kvar
System Generated kW
System Generated kW Percent
System Group Bus: Frequency
System Group Bus: Total PF
System Group Bus: Total var
System Group Bus: Total Watt
System Group Bus: Average Current
System Group Bus: Average Voltage
System Mains Bus: Frequency
System Mains Bus: Total PF
System Mains Bus: Total var
System Mains Bus: Total Watt
System Mains Bus: Average Current
System Mains Bus: Average Voltage
System Manager
System Online kvar Capacity
System Online kW Capacity
System Total kW Capacity
Total Fuel Used
Total Run Time
Var Demand
Var Mode
Volt Error
Volt PID
Voltage Bias Output
Watt Demand
Main Menu
Pressing the right arrow key while viewing the Overview screen opens the Main Menu screen. The Main
Menu screen options consist of Metering, Settings, and Summary. Metering screens primarily display
specific metering information. Settings screens primarily contain settings for configuring the
DGC-2020HD. The Summary screen consists of a one-line diagram of the system configuration, mains
fail transfer status, bus metering, and breaker command options.
Summary Screen
A one-line diagram, located at the top of the Summary screen, indicates system configuration and real
time breaker status. This one-line diagram is essentially the same as the one described in Overview
Screen above, except this diagram does not contain the shortcuts.
Mains fail transfer status is displayed just below the diagram. Mains fail transfer timers can be viewed by
selecting Mains fail transfer status (top line) and pressing the right arrow key. Press the left arrow key to
return to the Summary screen. See Metering chapter for details.
Metering of voltage, current, frequency, power, and power factor for the generator bus is displayed. Only
metered voltage and frequency for Bus 1 and Bus 2 are displayed.
Breakers in the system are listed at the bottom of the Summary screen. To send an open or close request
to a breaker in the system, move the cursor to the desired breaker in the list and press Edit. Press the up
PAGE 74 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
or down arrow keys to scroll the options. Press Edit again to send the selected breaker command
request. Breaker abbreviations are defined below:
• GB = Generator Breaker
• GGB = Generator Group Breaker
• MB = Mains Breaker
• TB = Tie Breaker
• TB2 = Tie Breaker 2
Front Panel Display Structure
The display structure of the Main Menu screens is provided below.
•
•
•
•
•
•
•
Metering
Engine
o Oil Pressure
o Coolant Temperature
o Battery Voltage
o Engine Speed
o Speed Source
o Fuel Level
o Engine Load
o Coolant Level
o Total Run Time
o Hours to Maintenance
o DEF Tank 1 Level (Visible when ECU Type is Standard, Volvo Penta, MTU SMC, MTU
ADEC, GM/Doosan, Cummins, MTU SMC)
o DEF Tank 2 Level (Visible when ECU Type is Standard, Volvo Penta, MTU SMC, MTU
ADEC, GM/Doosan, Cummins, MTU SMC)
Gen
o Voltage
o Current
o Frequency
o Power
o Energy
o Vector Shift
Bus 1
o Voltage
o Current
o Frequency
o Power
o Energy
Vector Shift
Bus 2
o Voltage
o Current
o Frequency
o Power
o Energy
o Vector Shift
Synchronization
Differential
o Phase A
o Phase B
o Phase C
o Phase Neutral
Bias Control
o Var Mode
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 75
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
•
•
•
•
•
•
•
•
•
•
•
•
•
o PF Mode
o Op Baseload Level
o Op kvar Setpoint
o Op PF Setpoint
Run Statistics
o Cumulative
o Session
Status
o Status
o Bus Condition
o IO Module Connected
o Run Request
o Mains Power Control
Inputs
o Contact Inputs
o Analog Input Values
o Remote Contact Inputs
o Remote Analog Input Values
o Logic Control Relays
o Remote System Manager Inputs
o Broadcast Logic
Outputs
o Contact Outputs
o Analog Outputs
o Configurable Elements
o Remote Contact Outputs
o Remote Analog Outputs
Configurable Protection
o Configurable Protection 1 to Configurable Protection 32
Alarms
Pre-Alarms
Event Log
o Show Log
o Reset
J1939 ECU
o J1939 Data (Visible when CAN Bus 2 ECU Support is enabled.)
o J1939 Engine Config (Visible when CAN Bus 2 ECU Support is enabled.)
o DTC Active Data (Visible when CAN Bus 2 ECU and DTC Support are enabled.)
o DTC Previous Data (Visible when CAN Bus 2 ECU and DTC Support are enabled.)
MTU
o MTU Fault Codes (Visible when selected ECU type is MTU MDEC, MTU ADEC, MTU
ECU7/8, and MTU Smart Connect.)
MTU Status (Visible when selected ECU type is MTU MDEC, MTU ADEC, MTU ECU7/8,
and MTU Smart Connect.)
System Status
o System Breaker Status
o System Mains Bus
o System Group Bus
o System Load Bus
o Power Breaker Sum
Real Time Clock
Gen Network Status
o Units
o Act Seg Units
o Units Online
o Sys Online kW Cap
PAGE 76 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
•
•
•
•
•
•
o Sys Online kvar Cap
o Sys Generated kW
o Sys Generated kW Percent
o Sys Generated kvar
o Sys Total kW Cap
o ID1 to ID32
Gen Sequencing
o Mode
o Next to Start
o Next Start UID
o Next to Stop
o Next Stop UID
o Start Timer 1
o Start Timer 2
o Stop Timer
o Seq Mode
o Sequence ID
o Unit ID
o Active Seg ID
o Sys Manager
o Sys Man UID
o Start TD 1
o Start TD 2
o Stop TD
Load Shedding
o Sys Total Seq Reserve
o Sys Online Reserve
o Priority to Shed
o Shed Delay
o Shed Fast Delay
o Priority to Add
o Add Delay
o Demand Start
o Load 1 to 64
Reports
o Sequence of Events
o Security Log
Diagnostics
o Control
o Load Share Line
o AEM-2020
o CEM-2020
o Mains Power
Settings
General Settings
o Front Panel HMI
o Device Information
o Access Control
o Clock Setup
o Display Units
Communication
o Ethernet
o Ethernet 2 (Visible when redundant Ethernet is disabled.)
o Redundant Ethernet
o CAN Bus 1 (I/O) Setup
o CAN Bus 2 (ECU) Setup
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 77
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
•
•
•
•
•
•
•
•
o Modem Setup
o RS485 Setup
o RS232 Setup
o Modbus Setup
o Email Setup
System Parameters
o System Settings
o Group Settings
o Rated Data
o Sensing Transformers
o Remote Module Setup
o Crank Settings
o Auto Restart
o Exercise Timer
o Relay Control
o Auto Config Detect
o Engine Statistics
o Seven Day Timer
Report Configuration
o Data Log
o Trending
o Sequence of Events Setup
Programmable Inputs
o Contact Inputs
o Analog Inputs
o Programmable Functions
o Remote Contact Inputs
o Remote Analog Inputs
o Remote RTD Inputs
o Remote Thermocouple Inputs
o Remote Sys Manager Inputs
Programmable Outputs
o Output Contacts
o Configurable Elements
o Remote Contact Outputs
o Remote Analog Outputs
Alarm Configuration
o Horn Configuration
o Pre-Alarms
o Alarms
o Sender Fail
o Prog Alarms
Protection
o Settings Group 0
o Settings Group 1
o Settings Group 2
o Settings Group 3
o Configurable Protection
Breaker Management
o Breaker Management
o Breaker Hardware
o Bus Condition
o Synchronizer
o Breaker Power Sum
Bias Control
o AVR Bias Control
o GOV Bias Control
o Mains Power Control
PAGE 78 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Multigen Management
o AVR Output
o GOV Output
o LS (Load Share) Output
o Demand Start/Stop
o Sequencing
o Network Configuration
o Load Shedding
Logic
o Logic Timers (1-8)
o Logic Timers (9-16)
o Logic Counters
o Broadcast Logic
Summary
System Configuration One-Line Diagram
Mains Fail St (Status)
o Mains Fail St (Status)
o Transfer Delay
o Max Transfer Time
o Return Delay
o Return Timer
o Max Parallel Time
o Open Transition Delay
Gen VLL
Gen Hz
Gen Aac
kW
kvar
PF (Power Factor)
PF Lead/Lag
Bus1 VLL
Bus1 Hz
Bus2 VLL (optional)
Bus2 Hz (optional)
GB Command (Visible when Generator Breaker control is enabled.)
o Open, Close, or None
GGB Command (Visible when Generator Group Breaker control is enabled.)
o Open, Close, or None
MB Command (Visible when Mains Breaker control is enabled.)
o Open, Close, or None
TB Command (Visible when Tie Breaker control is enabled.)
o Open, Close, or None
TB2 Command (Visible when Tie Breaker 2 control is enabled.)
o Open, Close, or None
Display Setup
®
BESTCOMSPlus Navigation Path: Settings Explorer, General Settings, Front Panel HMI
Front Panel Navigation Path: Settings > General Settings > Front Panel HMI
The DGC-2020HD LCD can be customized to fit the needs of your specific application. Most of the
options can be adjusted using the front panel buttons while all options can be adjusted within
BESTCOMSPlus. The display options are described below. Figure F shows the BESTCOMSPlus Front
Panel HMI settings screen. Settings are listed in Table B.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 79
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
Figure F. Front Panel Settings Screen
Table B. Settings for Front Panel Settings Screen
Locator
Setting
Range
Increment
Unit
A
Contrast Value
0 to 100
1
%
B
Invert Display
Enabled or Disabled
n/a
n/a
C
Sleep Mode
Enabled or Disabled
n/a
n/a
D
LCD Backlight Timeout
1 to 120
1
minutes
E
Language Selection
English, French, Spanish,
or German
n/a
n/a
F
Enable Scroll
Enabled or Disabled
n/a
n/a
G
Scroll Time Delay
1 to 600
varies
seconds
H
Phase Toggle Delay
0 to 120
1
seconds
I
Initializing Message
Up to 16 alphanumeric
characters
n/a
n/a
J
Touchscreen Disable
Enabled or Disabled
n/a
n/a
PAGE 80 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BASLER DGC-2020 PROGRAMMING APPENDIX (OPTION)
LCD Contrast
Adjust this setting to compensate for your LCD viewing angle, the available ambient light, or the ambient
temperature. This setting accepts values from 0 to 100, in increments of 1 percent.
Invert Display
When enabled, the LCD background is dark with light text.
Sleep Mode
Select enabled to send the DGC-2020HD into sleep mode during periods of inactivity to minimize battery
drain.
LCD Backlight Timeout
When Sleep Mode is enabled, this setting dictates the amount of time that must elapse before the DGC2020HD enters sleep mode. This setting accepts values from 1 to 120, in increments of 1 minute.
Language Selection
Front panel text is displayed in the selected language. Select English, French, Spanish, or German.
Screen Scrolling Setup
When scrolled metering is enabled, user-selected metering values are displayed on the overview screen.
Any number of the available values can be displayed. Up to nine values are displayed on the screen at
one time, after the scroll time delay has elapsed, the next set of values is displayed and so on.
Initializing Messages
Two custom initializing messages are displayed on the boot screen of the DGC-2020HD.
Touchscreen Disable
When checked, the touch screen controls are disabled.
Splash Screen
®
BESTCOMSPlus Navigation Path: Settings Explorer, General Settings, Splash Screen
Front Panel Navigation Path: Not available through front panel
A splash screen, which is displayed for a few seconds upon powering up the DGC-2020HD, can be
customized. The image must be exactly 480 pixels wide and 272 pixels high. Acceptable image formats
are BMP, JPG, GIF, and PNG. This is only available to units with the optional color touch screen (style
xTxxxxxxx).
Connect to the unit using BESTCOMSPlus. Click the Browse button on the Splash Screen, navigate to
the desired image, select it, and click Open. If successful, the image appears in the Splash Screen in
BESTCOMSPlus. Upload settings to the DGC-2020HD to transfer the image.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 81
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
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.
SAMPLE PARTS LIST
NO.
1
2%
2%
3
4
PART NO. PART NAME
QTY. REMARKS
12345
BOLT .....................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY
12347
WASHER, 3/8 IN. ..1 .....MQ-45T ONLY
12348
HOSE ..................A/R ...MAKE LOCALLY
12349
BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique symbol
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
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.
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
QTY. Column
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
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.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
PAGE 82 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
SUGGESTED SPARE PARTS
DCA220SSJU4F WHISPERWATT GENERATOR WITH JOHN DEERE
6068HFG09 DIESEL ENGINE
1 TO 3 UNITS
Qty.P/N
Description
2............M3311500503........HOSE, RADIATOR, UPPER
2............M3311500603........HOSE, RADIATOR, LOWER
3............R529383................BELT, FAN
1............RE556406..............FUEL FILTER KIT PRIMARY/SECONDARY
6............RE539279..............FILTER, OIL CARTRIDGE
3............P537876................ELEMENT AIR CLEANER PRIMARY
3............P537877................ELEMENT AIR CLEANER SAFETY
1............0601814013...........CIRCUIT BREAKER 1P 20A
1............0601814014...........CIRCUIT BREAKER 2P 50A
2............LY2DUS12VDC.....RELAY
1............0601806643...........FUSE, 15A
1............Y0601806647........FUSE, 25A
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 83
GENERATOR ASSY.
PAGE 84 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
C1110000102
ROTOR ASSY.....................................................1................INCLUDES ITEMS W/%
1-1%
FIELD ASSY.
1
1-2% 0601842334
RESISTOR, 80W, 100 OHM
1
1-3% 0601823282
RECTIFIER 1
1-4% 0018205020
HEX. SOCKET HEAD CAP SCREW
2
1-4A% 0032005000
WASHER, LOCK................................................2................REPLACES P/N 0040005000
1-4B% Y004120500
WASHER, FLAT
2
1-5%81%71070002 FAN
1
1-6% 8171611003
COUPLING DISK
9
1-7% C1164200004
WASHER, COUPLING HUB
1
1-8% 8171015003
BALANCING PLATE ..........................................1................ITEM 1-11 MUST BE ORDERED
WHEN REPLACING ITEM 1-8
1-9% 0012116045
HEX. HEAD BOLT
8
1-10% 0042616000
WASHER, LOCK
8
1-11% 0601000209
BALANCING WEIGHT KIT
1
1-12% C1112500004
BEARING FLANGE
1
1-13% 0071906314
BEARING 1
2%
M4163400003
COUPIING RING
1
3%
0343206120
HEX. HEAD BOLT
8
4%
0043606000
WASHER, LOCK
8
5%
0012112040
HEX. HEAD BOLT
8
6%
0042512000
WASHER, LOCK
8
7
C1130100103
STATOR ASSY.
1
7-1
0226100420
RUBBER SEAL
1
7-28171323004 CLAMPER
1
7-3
0223300120
RUBBER SEAL
1
7-48171323103 CLAMPER
1
7-5
Y0223100150
RUBBER SEAL
1
7-6
0010110035
HEX. HEAD BOLT
2
7-7
031110160
WASHER, FLAT..................................................2................REPLACES P/N 0041210000
7-8C1132200003 COVER
1
7-9
0226000510
RUBBER SEAL
2
7-10 0225000470
RUBBER SEAL
1
7-11 0017106016
HEX. HEAD BOLT
6
7-120601850144 GROMMET
1
8
C1154000002
END BRACKET
1
9
C1138000003
FIELD ASSY., EXCITER
1
10
0012110065
HEX. HEAD BOLT
4
10A 0042610000
WASHER, LOCK
4
10B 031110160
WASHER, FLAT..................................................4................REPLACES P/N 0041210000
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 85
GENERATOR ASSY. (CONT.)
PAGE 86 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
GENERATOR ASSY. (CONT.)
NO. PART NO.
11
0017112045
12
C1154400004
13
C1154300004
14
0010106060
14A 0040006000
14B 952404470
15
C1154400103
16
0017106016
17
C1132300114
18
0010006030
18A 952404470
18B020106050
19
0605000012
20
0030020000
20A 030220510
21
012010030
22
030210250
230070506307
PART NAME
QTY. REMARKS
HEX. HEAD BOLT
6
COVER, BEARING
1
GASKET, BEARING
1
HEX. HEAD BOLT
4
WASHER, LOCK
4
WASHER, FLAT..................................................4................REPLACES P/N 0041206000
SUCTION COVER
1
HEX HEAD BOLT
8
COVER, FAN
1
HEX HEAD BOLT................................................1................REPLACES P/N 0010106030
WASHER, FLAT..................................................1................REPLACES P/N 0041206000
NUT.....................................................................1................REPLACES P/N 0600815000
RUBBER SUSPENSION
2
HEX NUT
4
WASHER, LOCK................................................4................REPLACES P/N 0040020000
HEX HEAD BOLT...............................................12...............REPLACES P/N 0012110030
WASHER, LOCK...............................................12...............REPLACES P/N 0042510000
BEARING
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 87
CONTROL PANEL ASSY. (ECU 835)
PAGE 88 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CONTROL PANEL ASSY. (ECU 835)
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M4223000503
CONTROL PANEL
1
2
M9220100004
SET SCREW
2
2A0080200007 E-RING
2
3
M4223000604
CONTROL PANEL
1
4
0017108040
HEX. HEAD BOLT
4
50601840100KNOB..................................................................1................REPLACES P/N 0601840121
6
0601801040
CHANGE-OVER SWITCH, AMMETER
1
7
0601801041
CHANGE-OVER SWITCH, VOLTMETER
1
8
Y0602202651
ECU CONTROLLER
1
9
Y0602120569
GAUGE UNIT ASSY
1
10
Y0601810170
PANEL LIGHT, 12V
1
11
0027104020
MACHINE SCREW
2
11A OEMAA8
HEX. NUT...........................................................2................REPLACES P/N 0207004000
12
0601830710
PANEL LIGHT SWITCH
1
13
0601831205
PUSH BUTTON
1
14
82608
TOGGLE SWITCH..............................................1................REPLACES P/N 0601831340
150605011211 PIN
2
16
0601831557
EMERGENCY STOP BUTTON
1
17
0601807642
FREQUENCY METER 45~65HZ 240V
1
18
0601808992
AC AMMETER 0~400A/800A:5A
1
19
0601800275
AC VOLTMETER 0-600
1
20
0601840073
VOLT. REG., 20A, 1K
1
21
Y0206707000
HEX NUT
8
21A Y0044807000
WASHER, LOCK
8
22
M4246700604
WIRE HARNESS, GENERATOR
1
23
M5358200302
WIRE HARNESS, ENGINE
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 89
CONTROL PANEL ASSY. (BASLER DGC2020HD OPTION)
11A
12
11
1
2
12A
5
5
8
6
4
8
3
7
10
9
PAGE 90 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CONTROL PANEL ASSY. (BASLER DGC2020HD OPTION)
NO.
1
2%
3%
4%
5%
6%
7&
8%
9%
10%
11%
11A%
12%
12A%
PART NO.
EE59231 EE59122 EE59259
EE59123 EE55761 EE2115 EE9949 EE2591 EE57855 EE52893 EE23374 EE39554 EE23375 EE5895
PART NAME
QTY.
REMARKS
PANEL ASSY.,PARALLELING, DGC2020HD.....1 ...............INCLUDES ITEM W/%
PANEL, PARALLEL, BASLER DGC2020HD 1
CONTROLLER, DGC2020HD, COLOR
1
DECAL, PARALLEL, BASLER 2020HD
1
LIGHT, PANEL, LED POWERED, 12-36VDC 2
POTENTIOMETER, 5K OHM
1
NUT, SHAFT LOCK, POTENTIOMETER 1
SWITCH, TOGGLE, SPST
2
SWITCH, E-STOP, RED, 24V LED 1
BEZEL EMERG. STOP YELLOW PLASTIC 1
PUSHBUTTON, SWITCH (GREEN)
1
LED, 12V, GREEN
1
PUSHBUTTON, SWITCH (RED)
1
LED, 12V, RED
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 91
CONTROL BOX ASSY.
PAGE 92 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CONTROL BOX ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
12A
12B
13
14
15
16
16A
16B
16C
17
18
19
20
21
22
22A
23
23-1
24
24A
25
PART NO.
M4213000212
011008020
M5214400304
M4213500104
011008020
M3261500003
011008020
Y0602201458
011808015
0601821370
0027104020
LY2DUS12VDC
PTF08A
PYCA1
0027104020
0601815153
0027104020
M5214600004
0601806643
Y0601806647
M9501400304
Y0027203035
0601809667
011206020
0601820847
0601820848
0027104020
OEMAA8
Y0601807533
Y0601827412
014210040
021112140
0601820604
PART NAME
QTY.
REMARKS
CONTROL BOX
1
HEX. HEAD BOLT..............................................14...............REPLACES P/N 0016908020
BACK PANEL
1
UP PANEL
1
HEX. HEAD BOLT..............................................16...............REPLACES P/N 0016908020
SET PANEL
1
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908020
STARTER RELAY
1
MACHINE SCREW.............................................2................REPLACES P/N 0027106015
RECTIFIER DE-45..............................................1................REPLACES P/N 0601823240
MACHINE SCREW
1
RELAY, DC12V...................................................1................REPLACES P/N 0601827656
RELAY BASE......................................................1................REPLACES P/N 0601823109
RELAY CLIP.......................................................2................REPLACES P/N 0601824400
MACHINE SCREW
2
TERMINAL BLOCK
1
MACHINE SCREW
2
FUSE HOLDER ASSY
1
FUSE, 15A
2
FUSE, 25A
3
DECAL: FUSE HOLDER....................................1................M90140030
MACHINE SCREW
2
CURRENT TRANSFORMER
3
MACHINE SCREW.............................................6................REPLACES P/N 0027106020
OVER CURRENT RELAY
1
OVER CURRENT RELAY
1
MACHINE SCREW
2
HEX. NUT...........................................................2................REPLACES P/N 0207004000
CIRCUIT BREAKER 3P, 600A
1
REAR TERMINAL BUSBAR (SET)
2
HEX. HEAD BOLT...............................................6................REPLACES P/N 0017110040
SELF-LOCKING NUT.........................................6................REPLACES P/N 0207010000
AUTOMATIC VOLTAGE REGULATOR
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 93
CONTROL BOX ASSY. (CONTINUED)
PAGE 94 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CONTROL BOX ASSY. (CONTINUED)
NO. PART NO.
26
0027105015
27
M4273000003
28
011208030
29
8181852104
30
011606025
31
M427630000
32
M4276200004
33
012210020
34
0041410000
35
0040010000
36
014210040
36A 021112140
37
M4213600104
38
952404470
39
505015300
400330000250
PART NAME
QTY.
REMARKS
MACHINE SCREW
4
TERM. BRD., VOLTAGE CHANGE-OVER
1
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908030
CHANGE TERMINAL........................................10...............REPLACES P/N M4276400004
HEX. HEAD BOLT..............................................20...............REPLACES P/N 0017106025
CHANGE-OVER PLATE
6
CHANGE PLATE
3
TIE BOLT...........................................................26...............REPLACES P/N M9220100104
WASHER, FLAT
26
WASHER, LOCK
26
HEX. HEAD BOLT...............................................3................REPLACES P/N 0017110040
SELF-LOCKING NUT.........................................3................REPLACES P/N 0207010000
STOPPER, CONTROL PANEL
1
WASHER, FLAT..................................................1................REPLACES P/N 0041206000
SNAP PIN...........................................................1................REPLACES P/N 0605010502
EDGING
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 95
CONTROL BOX ASSY. (BASLER OPTION)
16
17
BASLER CONTROL PANEL
(REAR)
1
2
13
1
13
9
10
7
11
14
8
13
14
7
15
CONTROL BOX
(INSIDE)
6
5
3
4
PAGE 96 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CONTROL BOX ASSY. (BASLER OPTION)
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART NO.
EE55784 EE59124 EE56647 EE59127 EE50312 EE26385 EE10071 EE58130 EE26135
EE26112 EE58065 EE2940 EE32611 EE55785 EE38585 EE56188 EE59200 PART NAME
QTY.
CIRCUIT BREAKER (ABB), 3P, 10A, 480V 2
BRACKET, CONTACTOR
1
SWITCH (ABB), AUX/BELL
1
CONTACTOR (ABB), 650A, 100-250V 1
CABLE, ETHERNET, 10FT 2
RELAY BASE
2
RAIL, DIN, ALUM,.413" X 1.37" X 36"
1
RELAY, DC12V
2
RELAY CLIP
2
BLOCK, TERMINAL 14 POS.
1
ETHERNET SWITCH, 5 PORT 10-30VDC 1
END STOP, DIN RAIL
4
JUMPER, 3-POLE 2
SWITCH (ABB), AUX
2
CIRCUIT BREAKER (ABB), 2-POLE, 10A
1
CABLE, ETHERNET, ORANGE, 3 FT
1
HARNESS, PARALLELING
1
REMARKS
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 97
ETHERNET CABLE ASSY. (BASLER OPTION)
1
2
3
4
PAGE 98 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ETHERNET CABLE ASSY. (BASLER OPTION)
NO.
1
2
3
4
PART NO.
EE59027
EE55780 EE55760 EE58796 PART NAME
QTY.
REMARKS
TERMINAL BLOCK, 4-POS.
1
CABLE, ETHERNET CAT5E SHIELDED............1................50 FT
JACK, FEEDTHROUGH, RJ45, CAT5E
2
COVER, NONMETALLIC, WEATHERPROOF 1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 99
ENGINE AND RADIATOR ASSY.
PAGE 100 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENGINE AND RADIATOR ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M5924200014
ENGINE, JOHN DEERE 6068HFG09 1
1A
RE555046
ENGINE FAN......................................................1................REPLACES P/N Y0602060030
1B
RE544293
FAN CLUTCH, 12V.............................................1................REPLACES P/N Y0602061100
1C
Y0602060501
CAP SCREW
1
1D
R529383
FAN BELT...........................................................1................REPLACES P/N Y0602015207
1-1
RE539279
CARTRIDGE, OIL FILTER
1
1-2
RE556406
FUEL FILTER KIT, PRIMARY SECONDARY 1
1-3
RE553703
CARTRIDGE, BLOWBY FILTER.........................1................REPLACES P/N Y0602044231
2
0602046586
AIR CLEANER 1
2A
P537876
ELEMENT, PRIMARY.........................................1................REPLACES P/N 0602046682
2B
0602046683
ELEMENT, SAFETY
1
3
0602040558
AIR CLEANER BAND
2
3A
011208025
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908025
3B
020108060
SELF-LOCK NUT................................................4................REPLACES P/N 0207008000
4
0602040650
AIR CLEANER INDICATOR
1
5
0605515202
HOSE BAND
3
6
M5374100003
AIR CLEANER HOSE
1
7
M5374000404
AIR CLEANER PIPE
1
8
M5374200204
AIR CLEANER BRACKET
1
9
011008020
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908020
10
Y0602010222
SURGE TANK
1
11
Y0016908015
HEX. HEAD BOLT
4
12
Y0193602250
OVER FLOW HOSE
1
13
M5311400103
CAC PIPE (HOT SIDE)
1
14
Y0602015610
CAC HOSE
3
15
M3311400203
CAC PIPE (COLD SIDE)
1
16
Y0602325033
V-BAND CLAMP
1
17Y0602320206GASKET
1
18
0605515215
T-BOLT CLAMP
6
19
M3303200404
ENGINE FOOT
2
20
0012312030
HEX. HEAD BOLT...............................................6................REPLACES P/N 0013612030
20A 0040012000
WASHER, LOCK
6
21
0605515189
HOSE BAND
5
22
9500202080
HOSE BAND.......................................................4................REPLACES P/N 0605515178
23
Y0605511394
MINI BALL VALVE
1
24
0193600300
DRAIN HOSE
1
25
Y0603307520
45° ELBOW
1
26
M5327100004
BLOWBY PIPE
1
27
0265900480
BLOWBY HOSE
1
28
0605515149
HOSE BAND
3
29
Y0602012906
RADIATOR AND INTER-COOLER
1
30
M3311500503
RADIATOR HOSE, UPPER
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 101
ENGINE AND RADIATOR ASSY. (CONTINUED)
PAGE 102 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENGINE AND RADIATOR ASSY. (CONTINUED)
NO. PART NO.
31
M3311500603
32
Y0379100730
33
M5311501203
34
0605515201
35
Y0379101200
36
Y0605512192
370602022580
38
0602022561
39
Y0269201300
40
0603306395
41
0605511395
42
0603306590
43
0603300285
440602021070
45
Y0605000462
46
0030016000
46A 0040016000
47
M3314300104
480602326063
49
M5311200404
50
M5311200504
51
Y0016908015
52
011008020
53
M5311300603
54
M5311300703
55
011008020
56
M3311300803
57
M3311300903
58
011008020
590602220911
PART NAME
QTY.
REMARKS
RADIATOR HOSE, LOWER
1
VENT HOSE
1
SURGE TANK HOSE
1
HOSE BAND
2
VENT HOSE
1
HOSE JOINT
2
ADAPTER
1
90° ELBOW
1
PUSH-LOCK HOSE
1
MALE PIPE
1
BALL VALVE
1
MALE BULKHEAD CONNECTOR
1
BULKHEAD LOCKNUT
1
CAP
1
RUBBER SUSPENSION
2
HEX. NUT
4
WASHER, LOCK
4
CAC PIPE BRACKET
1
U-BOLT
2
RADIATOR BRACKET
1
RADIATOR BRACKET
1
HEX. HEAD BOLT
16
HEX. HEAD BOLT..............................................10...............REPLACES P/N 0016908020
FAN SHROUD
1
FAN SHROUD
1
HEX. HEAD BOLT..............................................12...............REPLACES P/N 0016908020
FAN GUARD
1
FAN GUARD
1
HEX. HEAD BOLT..............................................17...............REPLACES P/N 0016908020
CLAMP
2
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 103
OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
6-CATERPILLAR YELLOW
2-WHITE
7-CATO GOLD
3-SPECTRUM GREY
8-RED
4-SUNBELT GREEN
9-DESERT TAN
5-BLACK
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 104 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
OUTPUT TERMINAL ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
C1231700003
TERMINAL BOARD............................................1................REPLACES P/N M4230700003
2
M9220100304
OUTPUT TERMINAL BOLT
8
3
0801830804
TIE BOLT............................................................8................REPLACES P/N M9220100404
4
3461860504
TERMINAL PLATE..............................................3................REPLACES P/N M4233200004
5
0039316000
HEX. NUT
16
6
0040016000
WASHER, LOCK
24
7
0401450160
WASHER, FLAT.................................................32...............REPLACES P/N 0041416000
8
0016908040
HEX. HEAD BOLT
5
9
M4236100403
TERMINAL COVER
1
10
011106015
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016906015
110605010040 HINGE
2
12
0027103010
MACHINE SCREW
4
12A 0207003000
HEX. NUT...........................................................4................REPLACES P/N 0030003000
12B 0041203000
WASHER, FLAT
4
13
0027103015
MACHINE SCREW
4
13A 0207003000
HEX. NUT...........................................................4................REPLACES P/N 0030003000
14
M4236100504
OUTPUT WINDOW
1
15
M9220100804
SET SCREW
2
16
0040006000
WASHER, LOCK
2
17
952404470
WASHER, FLAT..................................................2................REPLACES P/N 0041206000
18
0080200005
E RING
2
19
M5454400003
TERMINAL COVER
1
20
0605050060
CONICAL LOCK WASHER
2
21
012212045
HEX. HEAD BOLT...............................................2................REPLACES P/N 0010112045
22
031112230
WASHER, FLAT..................................................6................REPLACES P/N 0041212000
23
0030012000
HEX. NUT
2
24 M4236400204COVER
1
25
011106015
HEX. HEAD BOLT...............................................8................REPLACES P/N 0016906015
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 105
OUTPUT TERMINAL ASSY. (CONTINUED)
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
6-CATERPILLAR YELLOW
2-WHITE
7-CATO GOLD
3-SPECTRUM GREY
8-RED
4-SUNBELT GREEN
9-DESERT TAN
5-BLACK
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 106 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
OUTPUT TERMINAL ASSY. (CONTINUED)
NO. PART NO.
PART NAME
QTY.
REMARKS
26
M4260600104
BRACKET, CIRCUIT BREAKER
1
26-1 0222100150
RUBBER CUSHION
1
27
011206020
HEX. HEAD BOLT...............................................2................REPLACES P/N 0016906020
28
0601808803
CIRCUIT BREAKER, 1P 20A
2
29
0601808804
CIRCUIT BREAKER, 2P 50A
3
30
0601814014
RECEPTACLE, 50A
3
31
0601814013
RECEPTACLE, 20A
2
32
0027104015
MACHINE SCREW
10
32A OEMAA8
HEX. NUT..........................................................10...............REPLACES P/N 0207004000
330601850275 GROMMET
1
34
0601815194
TERMINAL BLOCK
1
35
0027104015
MACHINE SCREW
2
36
0603306775
BLIND PLUG
2
37
0027104015
MACHINE SCREW
4
38
0019210025
HEX. HEAD BOLT
1
38A 0040510000
TOOTHED WASHER
1
39
M3237100204
INSULATING COVER
1
40 M4236400304BRACKET
1
41
011106015
HEX HEAD BOLT................................................2................REPLACES P/N 0016906015
42
M4236400004
CABLE OUTLET COVER
1
43
M4236400104
SUPPORTER, CABLE OUTLET COVER
1
44
011206020
HEX HEAD BOLT................................................8................REPLACES P/N 0016906020
45
HBL5278C
INLET FLANGE RECPT., 15 AMP NEMA, 125V....2................OPTION
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 107
CAMLOK PANEL ASSY. (OPTION)
PAGE 108 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
CAMLOK PANEL ASSY. (OPTION)
NO.
1
2%
3%
3%
4%
5%
6%
7%
8%
9%
10%
PART NO.
CAMLOK-2KITAL
EE6378 EE6380
EE6378 EE6381 EE6379 EE6382
EE56983 CL40WTC-L-125-J
EE26643 EE59031 PART NAME
QTY.
REMARKS
CAMLOK 2 SETS...............................................1................INCLUDES ITEMS/%
RECEPT, PANEL MNT., FEMALE, BLK, 4/0 2
RECEPT, PANEL MNT., FEMALE, RED, 4/0 2
RECEPT, PANEL MNT., FEMALE, BLK, 4/0 2
RECEPT, PANEL MNT., FEMALE, BLUE, 4/0 2
RECEPT, PANEL MNT., FEMALE, WHT, 4/0 2
RECEPT, PANEL MNT., FEMALE, GRN, 4/0 2
PANEL, TWO CONDUCT CAMLOK, ALU. 1
SNAP BACK PLASTIC COVER 10
TRANSFORMER,CURRENT,600:5
1
CAP, TERMINAL INSULATOR, BLACK 8
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 109
BATTERY ASSY.
PAGE 110 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BATTERY ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
10602220198BATTERY
1
2
M9103000504
BATTERY BAND
1
3
0602220921
BATTERY BOLT SET..........................................2................INCLUDES ITEMS W/$
3A$
WING NUT
2
3B$
PLASTIC WASHER
2
4
M9310500404
BATTERY SHEET
1
5
M5347900504
BATTERY CABLE
1
6
M5347900604
BATTERY CABLE
1
7
Y0010116030
HEX. HEAD BOLT
1
7A
0040016000
WASHER, LOCK
1
7B
0041216000
WASHER, FLAT
1
7C
0040516000
TOOTHED WASHER
1
8
0016910025
HEX. HEAD BOLT
1
8A
0040510000
TOOTHED WASHER
1
9
EARTH CABLE...................................................1................MAKE LOCALLY
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 111
MUFFLER ASSY.
PAGE 112 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
MUFFLER ASSY.
NO. PART NO.
1
RE560424
2
RE554144
3
RE565074
4
RE559456
5
RE540348
6
RE529640
7
RE560468
8RE556879
9
RE537624
10
RE304965
11
RE529510
12
Y0602325026
13
M5334100103
13A Y0400000800
14
M5334000203
14A Y0602311146
14B Y0602311147
15
RE540348
16
RE529640
170602326061
18
M5331401004
19
M5331401104
20
011008020
21
M5331200103
22
0016910025
23
M5331400604
24
M5331400904
25
011008020
26020108060
26A 401450080
27
Y0010116030
27A 0040016000
27B 0041216000
28
0605515202
29
011008020
PART NAME
QTY.
REMARKS
DIESEL PARTICULATE FILTER.........................1................REPLACES P/N Y0602330104
SCR CATALYST..................................................1................REPLACES P/N Y0602330302
DECOMPOSITION TUBE...................................1................REPLACES P/N Y0602330403
DECOMPOSITION EXTENSION TUBE.............1................REPLACES P/N Y0602330404
V-BAND CLAMP.................................................3................REPLACES P/N Y0602325034
SEALING RING..................................................3................REPLACES P/N Y0602320205
DEF INJECTOR..................................................1................REPLACES P/N Y0602330405
GASKET.............................................................1................REPLACES P/N Y0602330406
HEX. HEAD BOLT...............................................3................REPLACES P/N Y0602330407
V-BAND CLAMP.................................................1................REPLACES P/N Y0602325035
SEALING RING..................................................1................REPLACES P/N Y0602320204
PIPE BAND
1
TAIL PIPE
1
EXHAUST INSULATING WRAP
1
EXHAUST PIPE
1
EXHAUST INSULATING MATERIAL
1
EXHAUST INSULATING MATERIAL
1
V-BAND CLAMP.................................................1................REPLACES P/N Y0602325034
SEALING RING..................................................1................REPLACES P/N Y0602320205
U-BOLT
1
COVER, EXHAUST PIPE
1
BRACKET, EXHAUST PIPE
1
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908020
BRACKET, DPF AND SCR
1
HEX. HEAD BOLT
4
DPF BAND
1
SCR BAND
2
HEX. HEAD BOLT...............................................3................REPLACES P/N 0016908020
U-NUT.................................................................3................REPLACES P/N 0037908000
WASHER, FLAT..................................................3................REPLACES P/N 0041208000
HEX. HEAD BOLT
5
WASHER, LOCK
5
WASHER, FLAT
5
HOSE BAND
2
HEX. HEAD BOLT...............................................1................REPLACES P/N 0016908020
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 113
FUEL LINE ROUTING (PLUMBING) ASSY.
PAGE 114 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
FUEL LINE ROUTING (PLUMBING) ASSY.
NO. PART NO.
1
RE558330
2
M3331400503
3
011208060
3A
0401450080
3B020108060
4
011008020
5
RE552175
5A
RE554498
6
Y0010108090
6A
0040008000
6B
0401450080
7
RE560902
8
RE560900
9
RE560898
10 AT377287
11 TY22328
12 TY22328
13 0605515198
14 T317541
15 T296925
16 TY25141
17 Y0605515340
18 Y0602022585
19 0602022980
20 TY22326
21 TY22326
22 0605515198
23 0191300950
24 H216170
25 H216169
26 RE552182
27 RE552186
28 RE552185
29 011106015
30 RE542006
31 RE538131
32 011208030
33 RE544013
34 RE544012
35 RE543081
36 Y0603306489
37 RE542003
38 Y0603306488
39 M3331400804
40 011008020
41 RE560048
42 011106015
PART NAME
QTY.
REMARKS
DEF TANK ..........................................................1................REPLACES P/N Y0605500070
BRACKET, DEF TANK 1
HEX. HEAD BOLT ..............................................2................REPLACES P/N 0016908055
WASHER, FLAT .................................................2................REPLACES P/N 0041208000
U-NUT ................................................................2................REPLACES P/N 0037908000
HEX. HEAD BOLT ..............................................3................REPLACES P/N 0016908020
DEF SUPPLY MODULE .....................................1................REPLACES P/N Y0602330400
FILTER KIT ........................................................1................REPLACES P/N Y0602330414
HEX. HEAD BOLT 3
WASHER, LOCK 3
WASHER, FLAT .................................................3................REPLACES P/N 0041208000
DEF SUCTION LINE ..........................................1................REPLACES P/N Y0602330411
DEF BACKFLOW LINE ......................................1................REPLACES P/N Y0602330412
DEF PRESSURE LINE ......................................1................REPLACES P/N Y0602330413
HOSE BARB ......................................................1................REPLACES P/N Y0602022975
COOLANT HOSE ..............................................1................REPLACES P/N Y0379201000
COOLANT HOSE ..............................................1................REPLACES P/N Y0379200800
HOSE BAND 4
BLACK TEE-FITTING WITH ORIFICE ...............1................REPLACES P/N Y0602022976
WHITE TEE-FITTING ........................................1................REPLACES P/N Y0602022977
COOLANT HOSE ..............................................2................REPLACES P/N Y0379301300
HOSE BAND 6
90° ELBOW 1
HOSE JOINT 1
COOLANT HOSE ..............................................1................REPLACES P/N Y0379400850
COOLANT HOSE ..............................................1................REPLACES P/N Y0379400750
HOSE BAND 4
VENT HOSE 1
DEF TANK VENT FITTING ................................1................REPLACES P/N Y0602330402
DEF TANK VENT FILTER ..................................1................REPLACES P/N Y0602330401
NOX SENSOR ...................................................2................REPLACES P/N Y0602330410
SCR TEMP. SENSOR ........................................1................REPLACES P/N Y0602330409
DPF TEMP. SENSOR .........................................1................REPLACES P/N Y0602330204
HEX. HEAD BOLT ..............................................8................REPLACES P/N 0016906015
STRAP, TEMP. SENSOR ...................................2................REPLACES P/N Y0602330205
PRESSURE SENSOR .......................................1................REPLACES P/N Y0602330203
HEX. HEAD BOLT ..............................................2................REPLACES P/N 0016908030
FLEXIBLE LINE .................................................1................REPLACES P/N Y0602330002
FLEXIBLE LINE .................................................1................REPLACES P/N Y0602330001
JOINT .................................................................1................REPLACES P/N Y0602330201
SWIVEL JOINT 1
JOINT .................................................................1................REPLACES P/N Y0602330200
SWIVEL JOINT 1
SUPPLY MODULE BRACKET 1
HEX. HEAD BOLT ..............................................2................REPLACES P/N 0016908020
DEF HEADER ....................................................1................REPLACES P/N Y0602330408
HEX. HEAD BOLT ..............................................3................REPLACES P/N 0016906015
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 115
FUEL TANK ASSY.
PAGE 116 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
FUEL TANK ASSY.
NO.
1
1-1 2
3
4
5
5A
6
7
8
9
10 11 12 13 14 15 15A
16 PART NO.
M3364000402
0605505070
M4363200004
M9310500104
011008020
020108060
0401450080
0191302300
0191302800
Y0605515340
Y0602022577
Y0602022985
M1363400104
0605515198
1502025103C
011206020
0802011104
0150000018
Y0602022578
PART NAME
QTY.
REMARKS
FUEL TANK 1
FUEL TANK CAP 1
TANK BAND 2
SUPPORTER SHEET 4
HEX. HEAD BOLT ..............................................2................REPLACES P/N 0016908020
U-NUT ................................................................2................REPLACES P/N 0037908000
WASHER, FLAT .................................................2................REPLACES P/N 0041208000
SUCTION HOSE 1
RETURN HOSE 1
HOSE BAND 4
90° ELBOW 1
HOSE JOINT 2
DRAIN HOSE 1
HOSE BAND 2
DRAIN JOINT ....................................................1................REPLACES P/N M9200000003
HEX. HEAD BOLT ..............................................2................REPLACES P/N 0016906020
DRAIN BOLT ......................................................1................REPLACES P/N M9200200004
O-RING 1
90° ELBOW 1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 117
ENCLOSURE 1 ASSY.
PAGE 118 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENCLOSURE 1 ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1 M5414000302BASE
1
1A
0019208020
HEX. HEAD BOLT
1
1B
0040508000
TOOTHED WASHER
1
2 M1413400004COVER
1
3
011008020
HEX. HEAD BOLT...............................................2................REPLACES P/N 0016908020
4
M5424000702
FRONT FRAME
1
4A
M5494104303
ACOUSTIC SHEET
1
5
0016910025
HEX. HEAD BOLT
8
6
M3424200304
COVER, FRONT FRAME
1
6A
M3491200104
ACOUSTIC SHEET
1
7
0019208020
HEX. HEAD BOLT
22
8
M5424201703
OVER COVER, FRONT FRAME
1
9
0019208020
HEX. HEAD BOLT
15
10
M5434000302
CENTER FRAME
1
11
0010114040
HEX. HEAD BOLT
4
11A 030214350
WASHER, LOCK................................................4................REPLACES P/N 0040014000
11B 031114260
WASHER, FLAT..................................................8................REPLACES P/N 0041214000
11C 515455840
HEX. NUT...........................................................4................REPLACES P/N 0030014000
12
0010120050
HEX. HEAD BOLT
4
12A 030220510
WASHER, LOCK................................................4................REPLACES P/N 0040020000
12B 0041220000
WASHER, FLAT
8
12C 0030020000
HEX. NUT
4
13
M5444000202
REAR FRAME
1
13A M5494301504
ACOUSTIC SHEET
1
14
0016910025
HEX. HEAD BOLT
4
15
M4443300404
COVER, REAR FRAME
1
15A M4493302904
ACOUSTIC SHEET
1
16
0019208020
HEX. HEAD BOLT
14
17
M4443300503
DUCT, REAR FRAME
1
17A M4493303004
ACOUSTIC SHEET
1
18
020108060
HEX. NUT...........................................................9................REPLACES P/N 0207008000
19
M3444200303
DOOR, REAR FRAME
1
20 M9110100204HINGE
2
20AM9116100004 WASHER
2
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
6-CATERPILLAR YELLOW
2-WHITE
7-CATO GOLD
3-SPECTRUM GREY
8-RED
4-SUNBELT GREEN
9-DESERT TAN
5-BLACK
THE SERIAL NUMBER MAY BE REQUIRED.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 119
ENCLOSURE1 ASSY. (CONTINUED)
PAGE 120 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENCLOSURE 1 ASSY. (CONTINUED)
NO. PART NO.
PART NAME
QTY.
REMARKS
21
0845031504
BLIND PLUG.......................................................2................REPLACES P/N M9310000004
22
0019208020
HEX. HEAD BOLT
3
230601850097 STOPPER
1
24
0027208025
MACHINE SCREW
1
25
M4443600004
WINDOW PLATE
1
26
020106050
SELF-LOCKING U NUT......................................8................REPLACES P/N 0037906000
26A 952404470
WASHER, FLAT..................................................8................REPLACES P/N 0041206000
27
0600800320
MANUAL PAK
1
28
0027106016
MACHINE SCREW.............................................4................REPLACES P/N 0021806015
29
Y0605012309
DOOR HANDLE
1
30
0176060030
SELF-LOCKING NUT.........................................4................REPLACES P/N 0207006000
30A C9312500004
RUBBER SEAL
1
31
M5464100402
ROOF PANEL
1
31A M5494502704
ACOUSTIC SHEET
1
32
0019208020
HEX. HEAD BOLT
10
33 M3310600004COVER
1
34
0019208020
HEX. HEAD BOLT
4
35
0019210025
HEX. HEAD BOLT
4
36
M5464200202
ROOF PANEL
1
36A M5494502904
ACOUSTIC SHEET
1
37
0019208020
HEX. HEAD BOLT
16
38
0019210025
HEX. HEAD BOLT
4
39
M5464400003
DUCT, REAR ROOF
1
39A M4493503204
ACOUSTIC SHEET
1
40
011008020
HEX. HEAD BOLT..............................................10...............REPLACES P/N 0016908020
41
M4463200304
BACK PLATE
2
42
011106015
HEX. HEAD BOLT..............................................12...............REPLACES P/N 0016906015
43
M4463500204
ROOF BRACKET
2
44
0019206015
HEX. HEAD BOLT
8
45
M3317100004
BRACKET, SURGE TANK
1
46
011008020
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016908020
47
M3424700003
DEF TANK COVER
1
48
0019208020
HEX. HEAD BOLT
6
49
M3424700104
DEF TANK COVER
1
50
011106015
HEX. HEAD BOLT...............................................4................REPLACES P/N 0016906015
510601851736 GROMMET
2
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
6-CATERPILLAR YELLOW
2-WHITE
7-CATO GOLD
3-SPECTRUM GREY
8-RED
4-SUNBELT GREEN
9-DESERT TAN
5-BLACK
THE SERIAL NUMBER MAY BE REQUIRED.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 121
ENCLOSURE 2 ASSY.
PAGE 122 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
ENCLOSURE 2 ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M5454200302
SPLASHER PANEL
1
1A
M5491500004
ACOUSTIC SHEET
1
2
0019108065
HEX. HEAD BOLT
6
2A
0042308000
WASHER, LOCK
6
2B
031108160
WASHER, FLAT..................................................6................REPLACES P/N 0042408000
3
M5454000703
SIDE DOOR
1
3A
M3494406804
ACOUSTIC SHEET
1
4
M5454000803
SIDE DOOR
1
4A
M3494406904
ACOUSTIC SHEET
1
5
M5454000903
SIDE DOOR
1
5A
M3494407004
ACOUSTIC SHEET
1
6
M5454001003
SIDE DOOR
1
6A
M5494412804
ACOUSTIC SHEET
1
7 M3454300604DUCT
5
7A
M3494407204
ACOUSTIC SHEET
4
8 M5454300904DUCT
1
8A
M3494407504
ACOUSTIC SHEET
1
9 M5454301004DUCT
1
9A
M3494407304
ACOUSTIC SHEET
1
10
020108060
HEX. NUT..........................................................49...............REPLACES P/N 0207008000
11
M4453600104
DOOR BRACKET
5
12
M5454600004
DOOR BRACKET
2
13
0019206015
HEX. HEAD BOLT
21
14
Y0605012309
DOOR HANDLE
7
15
0176060030
SELF-LOCKING NUT........................................28...............REPLACES P/N 0207006000
160845046904 HINGE.................................................................5................REPLACES P/N M9110100804
16AM9116100004 WASHER
5
170845047004 HINGE.................................................................6................REPLACES P/N M9110100904
17AM9116100004 WASHER
6
18
0019208020
HEX. HEAD BOLT
25
190601850097 STOPPER
8
20
0027208025
MACHINE SCREW
8
21
0845031504
BLIND PLUG......................................................11...............REPLACES P/N M9310000004
ADD THE FOLLOWING DIGITS AFTER THE PART
NUMBER WHEN ORDERING ANY PAINTED PANEL TO
INDICATE COLOR OF UNIT:
1-ORANGE
6-CATERPILLAR YELLOW
2-WHITE
7-CATO GOLD
3-SPECTRUM GREY
8-RED
4-SUNBELT GREEN
9-DESERT TAN
5-BLACK
THE SERIAL NUMBER MAY BE REQUIRED.
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 123
RUBBER SEALS ASSY.
PAGE 124 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART NO.
0229201300
0229201200
0228901260
0228900690
0228900915
0228901155
0228901200
0228900630
0229400630
0228801050
0228800590
0228100560
0228100370
Y0229200145
Y0229200100
0222100200
PART NAME
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
SEAL RUBBER
SEAL RUBBER
QTY.
4
1
3
1
4
4
3
1
1
2
1
2
2
2
2
4
REMARKS
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 125
WATER HEATING ELEMENT ASSY. (OPTION)
PAGE 126 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
WATER HEATING ELEMENT ASSY. (OPTION)
NO. PART NO.
1
AR50411
2
EE54798
3
HBL5369C
4
EE56557
5$
6$
7$
8$
9$
PART NAME
QTY.
REMARKS
CORD ASSY., 110 VOLTS
1
KIT, 110 VOLT, COOLANT HEATER...................1................INCLUDES ITEMS W/$
CONNECTOR, 20 AMP, 125V
1
CORD, CAROL 3/C 14 AWG ............................10...............1PC=1FT
NUT, CLAMPING
1
ADAPTER
1
O-RING
1
HEATER ELEMENT, 1000 WATT
1
GASKET
1
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 127
BATTERY CHARGER ASSY. (OPTION)
PAGE 128 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
BATTERY CHARGER ASSY. (OPTION)
NO. PART NO.
1
EE57370
2
3
EE56557
4
5
6
7
8
PART NAME
QTY.
REMARKS
CHARGER BATTERY, 10 AMP 12/24V..............1
GROMMENT, 7/8" HOLE SIZE...........................1................OBTAIN LOCALLY
CORD, 3-CONDUCTOR, 14 AWG ..................6 FT...............1PC=1FT
SCREW, M4X10.................................................4................OBTAIN LOCALLY
WASHER, LOCK M4..........................................4................OBTAIN LOCALLY
WASHER, FLAT M4............................................4................OBTAIN LOCALLY
WIRE, 16GA, RED ......................................... 9 FT...............OBTAIN LOCALLY
WIRE, 16GA, GREEN..................................... 9 FT...............OBTAIN LOCALLY
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 129
NAMEPLATE AND DECALS ASSY.
PAGE 130 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
NAMEPLATE AND DECALS ASSY.
NO. PART NO.
1-1
M3551000103
1-2
M3551000303
1-3
M9520100304
1-4
M9520100603
1-5
M3551000603
2-1
M5551000602
2-2
M9520000104
2-3
M9520000204
2-4
M9520100004
2-5
M9520100704
2-6
M9520200404
2-7
M9522000504
2-8
M9520200303
2-9
M9520200504
3-1
M9500000004
3-2
M9500100004
3-3
M9503000004
3-4
M9503000103
3-5
M9503100004
3-6
M9510100004
3-7
M9501300004
4-1
M4550000503
4-2
M9520000004
4-3
M9520000504
4-4
M9520000704
4-5
M9520100404
4-6
M9520100503
5-1
M9500300004
5-2
M9500300104
5-3
M951000403
PART NAME
QTY.
REMARKS
DECAL: OPERATING PRECAUTIONS...............1................M35100010
DECAL: DPF REGENERATION PROCED..........1................M35100030
DECAL: SAFETY INSTRUCTIONS....................1................M92010030
DECAL: CAUTION..............................................2................M92010060
DECAL: SCR INDICATOR..................................1................M35100060
CONTROL PANEL AND BOX GROUP
DECAL: CONTROL PANEL................................1................M55100060
PLATE: AMMETER CHANGE-OVER SW. .........1................M92000010
PLATE: VOLTMETER CHANGE-OVER SW. ......1................M92000020
DECAL: WARNING: ELECT. SHCK. HAZARD....2................M92010000
DECAL: WARNING: ARC FLASH.......................1................M92010070
DECAL: O. C. R. RESET.....................................1................M92020040
DECAL: CIRCUIT BREAKER.............................1................M92200050
DECAL: SETTING FOR OUTPUT VOLTAGE.....1................M92020030
DECAL: SETTING FOR OUTPUT VOLTAGE(S).1................M92020050
ENGINE AND RADIATOR GROUP
DECAL: OIL DRAIN............................................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
DECAL: CAUTION: BATTERY CABLES.............1................M90130000
OUTPUT TERMINAL GROUP
DECAL: RECEPTACLE & CIRC. BREAKER.......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
DECAL: -.............................................................1................M90030000
DECAL: +............................................................1................M90030010
DECAL: CAUTION..............................................1................M91010040A
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 131
NAMEPLATE AND DECALS ASSY. (CONT.)
PAGE 132 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
NAMEPLATE AND DECALS ASSY. (CONT.)
NO. PART NO.
PART NAME
QTY.
REMARKS
MUFFLER GROUP
6-1
M9503200004
DECAL: WARNING: ENGINE EXHAUST............1................M90320000
6-2
M9503200104
DECAL: DANGER: EXHAUST............................1................M90320010
6-3
920214100
DECAL; WARNING: START FIRES....................1................REPLACES P/N M9504200004
M90420000
FUEL TANK GROUP
7-1
M9501500004
DECAL: DIESEL FUEL.......................................2................M90150000
7-2
M9500500104
DECAL: FUEL DRAIN PLUG..............................1................M90050010
7-3
M9501500104
DECAL: DIESEL EXHAUST FLUID....................1................M90150010
7-4
M9504500004
DECAL: REFILL DEF AS WELL.........................1................M90450000
ENCLOSURE GROUP
8-1
M9511200204
DECAL: MQ........................................................1................M91120020
8-20600500092 EMBLEM
1
0021106015
MACHINE SCREW
4
8-3M4560100704 STRIPE
2
8-4M5561101104 STRIPE
2
8-5M5561101204 STRIPE
1
8-6M3561100203 STRIPE
2
8-7M4560100003 STRIPE
1
8-8M5561101004 STRIPE
1
8-9
M3550002204
DECAL: CAUTION..............................................1................M35000220
8-10 M9512000004
DECAL: SUPPORT HOOK.................................2................M91200000
8-11 M9510000104
DECAL: DOCUMENT BOX LOCATED ..............1................M91000010
8-12 M9511200103
DECAL: TIER 4F.................................................1................M91120010
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 133
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
5.
Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
6.
The following items are not returnable:
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.
a.
SPECIAL EXPEDITING SERVICE
Terms of payment for parts are net 30 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
b.
MINIMUM ORDER
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
RETURNED GOODS POLICY
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
1.
A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
2.
Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
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.
c.
Any line item with an extended
dealer net price of less than
$5.00.
d.
Special order items.
e.
Electrical components.
f.
Paint, chemicals, and lubricants.
g.
Decals and paper products.
h.
Items purchased in kits.
7.
The sender will be notified of any material
received that is not acceptable.
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.
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.
a.
The parts numbers and descriptions
must match the current parts price
list.
9.
b.
The list must be typed or computer
generated.
Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
c.
The list must state the reason(s)
for the return.
d.
The list must reference the sales
order(s) or invoice (s) under
which the items were originally
purchased.
e.
The list must include the name
and phone number of the person
requesting the RMA.
3.
A copy of the Return Material Authorization
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.
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.
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
LIMITATIONS OF SELLER’S LIABILITY
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
LIMITATION OF WARRANTIES
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
Effective: February 22, 2006
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
PAGE 134 — DCA220SSJU4F 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #1 (06/17/16)
NOTES
DCA220SSJU4F 60 HZ GENERATOR• OPERATION AND PARTS MANUAL — REV. #1 (06/17/16) — PAGE 135
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
Contact: mq@multiquip.com
MQ Parts Department
Tel. (800) 421-1244
Fax (310) 537-3927
Service Department
800-421-1244
310-537-3700
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
Fax: 310-537-4259
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
Fax: 310-943-2238
CANADA
UNITED KINGDOM
Multiquip
Multiquip (UK) Limited Head Office
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: infocanda@multiquip.com
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: sales@multiquip.co.uk
Tel: 0161 339 2223
Fax: 0161 339 3226
© COPYRIGHT 2016, 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:
Manufactured for
Multiquip Inc.
by
DENYO CO., LTD, JAPAN