WHISPERWATT SERIES MODEL DCA-15SPXU4service.multiquip.com/pdfs/DCA15SPXU4-rev-0-manual.pdf · WHISPERWATTTM SERIES MODEL DCA-15SPXU4 60 Hz GENERATOR. ... Model KUBOTA V2203-M Type

PARTS AND OPERATION MANUALOPERATION MANUAL

Revision #0 (03/31/11)

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.

WHISPERWATTTM SERIESMODEL DCA-15SPXU4

60 Hz GENERATOR

PAGE 2 — DCA-15SPXU4— OPERATION MANUAL — REV. #0 (03/31/11)

Diesel engine exhaust and some of

PROPOSITION 65 WARNING

DCA-15SPXU4— OPERATION MANUAL — REV. #0 (03/31/11) — PAGE 3

1

NOTE PAGE


TABLE OF CONTENTS

NOTE

MQ POWER DCA-15SPXU4MQ POWER DCA-15SPXU4MQ POWER DCA-15SPXU4MQ POWER DCA-15SPXU4MQ POWER DCA-15SPXU4WHISPERWHISPERWHISPERWHISPERWHISPERWWWWWAAAAATTTTTTTTTTTMTMTMTMTM GENERATORGENERATORGENERATORGENERATORGENERATORCalifornia Proposition 65 Warning ..................................... 2Table Of Contents ............................................................. 4Parts Ordering Procedures ............................................... 5Specifications ................................................................... 6Dimensions (Top, Side, Front) .......................................... 7Safety Message Alert Symbols .................................... 8-9Rules for Safe Operation ........................................... 10-14Installation ................................................................. 16-17General Information ........................................................ 18Major Components ......................................................... 19Generator Control Panel ............................................ 20-21Output Terminal Panel Familiarization ........................ 22-24Load Application/Max Amperage .................................... 25Gauge Reading/Terminal Panel Connections .................. 26Setup ......................................................................... 27-30Generator Start-up Procedure ................................... 31-32Generator Shut-Down Procedure .................................... 33Maintenance (Engine) ................................................ 34-36Maintenance (Trailer) ................................................. 37-39Generator Wiring Diagram ............................................... 40Engine Wiring Diagram ................................................... 41Troubleshooting (Engine) ........................................... 42-43Troubleshooting (Generator) ............................................ 44Troubleshooting (Pre-Heat Lamp Codes) ........................ 45

Specification and partnumber are subject tochange without notice.


1

NOTE PAGE


DCA-15SPXU4 — SPECIFICATIONS

Table 1. Generator Specifications

Model DCA-15SPXU4

Type Revolving field, self ventilated, open protected type synchronousgenerator

Phase Single Phase 3-Wire

Standby Output 16.5 KW

Prime Output 15 KW

Voltage 240V/120

Frequency 60 Hz

Speed 1800 rpm

Power Factor 1.0

Aux. AC Power(GFCI) 2.4 KW @120 VAC Single Phase, 60 Hz

Aux. AC Power(L5-30R) 3.6 KW@120 VAC Single Phase, 60 Hz

Aux. AC Power(L6-30R ) 7.2 KW@240 VAC Single Phase, 60 Hz

Aux. AC Power(CS6369)

12 KW@240 VAC Single Phase, 60 Hz6 KW@120 VAC Single Phase, 60 Hz

Table 2. Engine Specifications

Model KUBOTA V2203-M

Type 4 Cycle, water-cooled, swirl combustion chamber type

No. of Cylinders 4 cylinders

Bore x Stroke 3.43 in. x 3.64 in. (87 mm x 92.4 mm)

Rated Output 27.1 HP/1800 rpm

Displacement 134.1 cu. in. (2,197 cc)

Starting Electric

Coolant Capacity 2.09 gal. (7.9 liters)

Lube Oil Capacity 2.00 gal. (7.6 liters)

Fuel Tank Capacity 16.4 gal. (62 liters)

Fuel Consumption1.37 gal. (5.2 L)/hr at full load 1.08 gal. (4.08 L)/hr at 3/4 load

0.83 gal. (3.14 L)/hr at 1/2 load 0.62 gal. (2.34 L)/hr at 1/4 load

Battery 12V- 65AH (27:525A)

Fuel #2 Diesel Fuel

Dry Weight 577 kg

Total Weight 649 kg


1

DCA-15SPXU4 — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

WHISPERWATT15 MQPOWER

FRONT VIEW

F

E

D

TOP VIEW

SIDE VIEW

Denyo

BC

A

U N V

TABLE 3. DIMENSIONS

Reference Letter Dimension in. (mm.)

A 21.65 (550)

B 20.07 (510)

C 21.85 (555)

D 61.02 (1,550)

E 35.43 (900)

F 25.60 (650)


This Owner's Manual has beendeveloped to provide completeinstructions for the safe andefficient operation of theMQ Power Model DCA-15SPXU4Whisperwatt™ Generator.

Before using this generator, ensure that the operatingindividual has read and understands all instructions inthis manual.

Safety precautions should be followed at all times whenoperating this equipment. Failure to read and understand theSafety Messages and Operating Instructions could result ininjury to yourself and others.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS

Potential hazards associated with the operation of thisequipment will be referenced with "Hazard Symbols" whichappear throughout this manual, and will be referenced inconjunction with Safety "Message Alert Symbols".

NOTE

DCA-15SPXU4 — SAFETY MESSAGE ALERT SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform youabout potential hazards that could injure you or others. TheSafety Messages specifically address the level of exposureto the operator, and are preceded by one of three words:DANGER, WARNING, or CAUTION.

You WILL be KILLED or SERIOUSLY injured if youdo not follow directions.

You COULD be KILLED or SERIOUSLY injured ifyou do not follow directions.

You CAN be injured if you do not follow directions

Gasoline engine exhaust gases containpoisonous carbon monoxide. This gas iscolorless and odorless, and can causeDEATH if inhaled. NEVER operate this

equipment in a confined area or enclosed structure thatdoes not provide ample free flow air.

Diesel fuel is extremely flammable, andits vapors can cause an explosion ifignited. DO NOT start the engine nearspilled fuel or combustible fluids.DO NOT fill the fuel tank while the engineis running or hot.

DO NOT overfill tank, since spilled fuel could ignite if itcomes into contact with hot engine parts or sparks fromthe ignition system. Store fuel in approved containers, inwell-ventilated areas and away from sparks and flames.NEVER use fuel as a cleaning agent.

Engine components can generate extremeheat. To prevent burns, DO NOT touch theseareas while the engine is running orimmediately after operations. NEVERoperate the engine with heat shields or heatguards removed.

WARNING

DANGER

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, thereexists the possibility of electrocution,electrical shock or burn, which can causesevere bodily harm or even DEATH!

DANGER - ELECTROCUTION HAZARDS


1

DCA-15SPXU4 — SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the engine ON/OFFswitch (MPEC) in the OFF/RESETposition when the generator is not in use.

ALWAYS wear approved respiratoryprotection.

ALWAYS wear approved eye andhearing protection.

Other important messages are provided throughout thismanual to help prevent damage to your generator, otherproperty, or the surrounding environment.

This generator, other property, orthe surrounding environmentcould be damaged if you do notfollow instructions.

NOTE

NEVER tamper with the factory settingsof the engine governor or settings.Personal injury and damage to the engineor equipment can result if operating inspeed ranges above maximum allowable.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,or guards removed. Keep fingers, hands,hair and clothing away from all movingparts to prevent injury.

WARNING - ROTATING PARTS

Wet-Stacking is a common problem with diesel engineswhich are operated for extended periods with light or noload applied. When a diesel engine operates withoutsufficient load (less than 40% of the rated output) it willnot operate at its optimum temperature. This will allowunburned fuel to accumulate in the exhaust system, whichcan foul the fuel injectors, engine valves and exhaustsystem, including turbocharges, and reduce the operatingperformance.In order for a diesel engine to operate at peak efficiency itmust be able to provide fuel and air in the proper ratio andat a high enough engine temperature for the engine tocompletely burn all of the fuel.Wet stacking does usually cause any permanent damageand can be alleviated if additional load is applied to relievethe condition. It can reduce the system performance andincrease maintenance. Applying an increasing load over aperiod of time until the excess fuel is burned off and thesystem capacity is reached usually can repair the condition.This can take several hours to burn off the accumulatedunburned fuel.

CAUTION - ENGINE LOAD (WET-STACKING)


DCA-15SPXU4 — RULES FOR SAFE OPERATION

The following safety guidelines should always be used whenoperating the DCA-15SPXU4 Whisperwatt™ AC Generator.

General Safety:

■ DO NOT operate or service thisequipment before reading this entiremanual.

The operator MUST BE familiar with proper safetyprecautions and operations techniques before usinggenerator.

■ This equipment should not be operated by persons under18 years of age.

■ NEVER operate this equipment without proper protectiveclothing, shatterproof glasses, steel-toed boots and otherprotective devices required by the job.

■ NEVER operate this equipment when notfeeling well due to fatigue, illness or takingmedicine.

■ NEVER operate this equipment under the influence ordrugs or alcohol.

Failure to follow instructions in this manual may lead toserious injury or even DEATH! This equipment is to beoperated by trained and qualified personnel only! Thisequipment is for industrial use only.

DANGER - READ THIS MANUAL!

■ ALWAYS wear proper respiratory (mask),hearing and eye protection equipment whenoperating the generator.

■ Whenever necessary, replace nameplate, operation andsafety decals when they become difficult read.

■ Manufacturer does not assume responsibility for anyaccident due to equipment modifications. Unauthorizedequipment modification will void all warranties.

■ NEVER use accessories or attachments, which are notrecommended by Multiquip for this equipment. Damageto the equipment and/or injury to user may result.

■ The engine section of this generators requires an adequatefree flow of cooling air. NEVER operate the generator inany enclosed or narrow area where free flow of the air isrestricted. If the air flow is restricted it will cause seriousdamage to the generatorsor engine and may causeinjury to people.Remember the generator'sengine gives off DEADLYcarbon monoxide gas.

■ NEVER touch the hot exhaustmanifold, muffler or cylinder.Allow these parts to cool beforeservicing engine or generators.

■ ALWAYS refuel in a well-ventilated area, away from sparksand open flames.

■ ALWAYS use extreme caution whenworking with flammable liquids. Whenrefueling, stop the engine and allow it tocool. DO NOT smoke around or near themachine. Fire or explosion could resultfrom fuel vapors, or if fuel is spilled on ahot engine.

■ NEVER operate the generator in anexplosive atmosphere or nearcombustible materials. An explosion orfire could result causing severe bodilyharm or even death.

■ NEVER disconnect any "emergency or safety devices".These devices are intended for operator safety. Disconnectionof these devices can cause severe injury, bodily harm or evendeath! Disconnection of any of these devices will void allwarranties.

DANGEROUSGAS FUMES

Denyo


1


■ ALWAYS be sure the operator is familiar with proper safetyprecautions and operation techniques before usinggenerators.

■ NEVER leave the generator unattended, turn off engine whenunattended.

■ Unauthorized equipment modifications will void all warranties.

■ ALWAYS ensure generator is on level ground before use.

■ DO NOT place hands or fingers inside generators enginecompartment when engine is running.

■ NEVER run engine without air cleaner. Severe engine damagemay occur.

■ NEVER change or adjust the engine speed which has beenset at the factory prior to shipping.

Power Cord Safety■ NEVER let power cables or cords lay in water.

■ NEVER stand in water while AC power from the generatorsis being transfer to a load.

■ NEVER use a defective or frayed power cable. Check thecable for cuts in the insulation.

■ NEVER use a extension cord that is frayed or damaged wherethe insulation has been cut.

■ ALWAYS make certain that proper power or extension cordhas been selected for the job See Table 6.

Grounding Safety■ ALWAYS make sure that electrical circuits are properly

grounded per the National Electrical Code (NEC) andlocal codes before operating generator. Severe injury ordeath! by electrocution can result from operating anungrounded generator.

■ ALWAYS make sure the generators are properly grounded toa suitable earth ground (GROUND ROD). See installation inthis manual.

■ NEVER use gas piping as an electrical ground.

Maintenance Safety■ NEVER lubricate components or attempt service on a running

machine.

■ High Temperatures – Always stop engine andallow the engine to cool before adding fuel, oilor performing service and maintenancefunctions. Contact with hot! components cancause serious burns.

■ Keep the machinery in proper running condition.

■ Fix damage to the machine immediately and replace anybroken parts immediately.

■ ALWAYS replace any worn or damaged warning decals.

■ ALWAYS store equipment properly when it is not being used.Equipment should be stored in a clean, dry location out of thereach of children and un-authorized personnel.

■ The electrical voltage required to operate the generator cancause severe injury or even death through physical contactwith live circuits. Turn all circuit breakers OFF beforeperforming maintenance on the generator.

■ Dispose of hazardous waste properly. Examples of potentiallyhazardous waste are used motor oil, fuel and fuel filters.

■ DO NOT use food or plastic containers to dispose ofhazardous waste.

■ DO NOT pour waste, oil or fuel directly onto the ground,down a drain or into any water source.

■ ALWAYS allow the machine a proper amount of time tocool before servicing.

■ ALWAYS service air cleaner frequently to prevent enginemalfunction.

■ ALWAYS disconnect the NEGATIVE battery terminalbefore performing service on the generator.

■ Follow all battery safety guidelines listed in this manualwhen handleing or servicing the generator.



Battery Safety

Use the following guidelines when handling the battery:

■ The battery contains acids that cancause injury to the eyes and skin. Toavoid eye irritation, always wear safetyglasses.

■ Use well insulated gloves when picking up the battery.

■■■■■ ALWAYS keep the battery charged. If the battery is notcharged a buildup of combustible gas will occur.

■■■■■ ALWAYS keep battery charging and cables in goodworking condition. Repair or replace all worn cables.

■■■■■ ALWAYS recharge the battery in an vented airenvironment, to avoid risk of a dangerous concentrationof combustible gases.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with clothing or skin, rinse skin or clothingimmediately with plenty of water.

■■■■■ In case the battery liquid (dilute sulfuric acid) comes incontact with your EYES, rinse eyes immediately withplenty of water and contact the nearest doctor or hospitalto seek medical attention.

The risk of an explosion exists when performing serviceon the battery. To avoid severe injury or DEATH:

■■■■■ DO NOT drop the battery. Thereis the possibility of risk that thebattery may explode.

■■■■■ DO NOT expose the battery toopen flames, sparks, cigarettesetc. The battery contains combustible gases and liquids.If these gases and liquids come in contact with a flameor spark, an explosion could occur.

DANGER - EXPLOSION HAZARDS

To prevent burns, DO NOT touch or open any of the belowmentioned components while the engine isrunning or immediately after operations.Always allow sufficient time for the engineand generator to cool before performingmaintenance.

■ Radiator Cap - Removing the radiator cap while theengine is hot will result in high pressurized, boiling waterto gush out of the radiator, causing severe scalding toany persons in the general area of the generator.

■ Coolant Drain Plug - Removing thecoolant drain plug while the engine ishot will result in hot coolant gushingout of the coolant drain plug, thereforecausing severe scalding to any personsin the general area of the generator.

■ Engine Oil Drain Plug - Removing the engine oil drainplug while the engine is hot will result in hot oil gushingout of the oil drain plug, therefore causing severescalding to any persons in the general area of thegenerator.



1


Backfeed to a utility system can causeelectrocution and or property damage.NEVER connect the generators to abuilding's electrical system without atransfer switch or other approved device.All installations should be performed bya licensed electrician in accordancewith all applicable laws and electricalcodes. Failure to do so could result inelectrical shock or burn causing seriousinjury or even death!

Emergencies

■ ALWAYS know the location of thenearest fire extinguisher.

■ ALWAYS know the location of the nearestfirst aid kit.

■ In emergencies always know the location of thenearest phone or keep a phone on the job site.Also know the phone numbers of the nearestambulance, doctor and fire department. Thisinformation will be invaluable in the case of anemergency.

DANGERDANGERDANGERDANGERDANGER-Electrocution HazardsElectrocution HazardsElectrocution HazardsElectrocution HazardsElectrocution Hazards

During operation of this generation, thereexists the possibility of electrocution,electrical shock or burn, which cancause severe bodily harm or evenDEATH!To avoid these hazards:

NEVER use damaged or worn cables when connectingequipment to the generator. Make sure power connectingcables are securely connected to the generator’s outputreceptacles, incorrect connections may cause damageto the generators and electrical shock.

NEVER insert any objects intothe output receptacles duringoperation. This is extremelydangerous. ALWAYS turn-offthe generators and place all circuit breakers in the “OFF”position when contact with the output receptacles isrequired. There exist the possibility of electrocution,electrical shock or burn, which can cause severebodily harm or even death!

NEVER grab or touch a livepower cord with wet hands, thepossibility exist of electricalshock, electrocution, and evendeath!

AC CIRCUITBREAKER

AC CIRCUITBREAKER

OFF

OFF

22A

22A

120

V

20A

120V

OFFOFF

ON

GA-2.9R

2900

DANGERUsing a generator indoors .CAN KILL YOU IN MINUTES

Generator exhaust contains carbon monoxide. This isa posion you cannot see or smell

NEVER use inside a homeor garage, even if doorsand windows are open

AC CIRCUITBREAKER

AC CIRCUITBREAKER

OFF

OFF

22A

22A

120

V

20A

120V

OFF

ON

GA-2.9R

2900

AC CIRCUITBREAKER

AC CIRCUITBREAKER

OFF

OFF

22A

22A

120

V

20A

120V

OFF

ON

GA-2.9R

2900

Only use OUTSIDE andfar away from windows,doors, and vents.

Avoid other generator hazards..READ MANUAL BEFORE USE

Engine exhaust gases containpoisonous carbon monoxide. This gasis colorless and odorless, and cancause death if inhaled. NEVER operatethis equipment in a confined area orenclosed structure that does not provideample free flow air.

DANGERDANGERDANGERDANGERDANGER-Lethal Exhaust Gas HazardsLethal Exhaust Gas HazardsLethal Exhaust Gas HazardsLethal Exhaust Gas HazardsLethal Exhaust Gas Hazards


Check with your local county or state safety towingregulations, in addition to meeting Department ofTransportation (DOT) Safety Towing Regulations, beforetowing your generator.

CAUTION - FOLLOW TOWING REGULATIONS

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place chock blocks underneath wheel to prevent rolling,while parked.

■ Use the trailer’s swivel jack to adjust the trailer height toa level position while parked.

■ Avoid sudden stops and starts. This can cause skidding,or jack-knifing. Smooth, gradual starts and stops willimprove towing.

■ Avoid sharp turns.

■ Trailer should be adjusted to a level position at all timeswhen towing.

■ Raise and lock trailer wheel stand in up position whentransporting.

■ The maximum speed for highway towing is 55 MPHunless posted otherwise. Recommended off-road towingis not to exceed 15 MPH or less depending on type ofterrain.

■ Place support blocks underneath the trailer’s bumper toprevent tipping, while parked.

■ Avoid sharp turns to prevent rolling.

■ DO NOT transport generator with fuel in tank.

Towing and Transporting Safety

To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailerthat supports the generator and the towing vehicle are ingood operating condition and both units are mechanicallysound.

The following list of safety precautions should be followedwhen towing your generator:

■ ALWAYS shutdown engine before transporting.

■ Drain fuel from generator fuel tank before towing.

■ If generator is mounted on a trailer, make sure trailercomplies with all local and state safety transportationlaws. Follow the listed Towing & Transporting Safetyguidelines for basic towing techniques.

■ Make sure the hitch and coupling of the towing vehicleare rated equal to, or greater than the trailer "gross vehicleweight rating.”

■ ALWAYS inspect the hitch and coupling for wear. NEVERtow a trailer with defective hitches, couplings, chains etc.

■ Check the tire air pressure on both towing vehicle andtrailer. Trailer tires should be inflated to 50 psi cold.Also check the tire tread wear on both vehicles.

■ ALWAYS make sure the trailer is equipped with a "SafetyChain".

■ ALWAYS attach trailer’s safety chains to towing vehicleproperly.

■ ALWAYS make sure the vehicle and trailer directional,backup, brake, and trailer lights are connected andworking properly.

■ DOT Requirements include the following: Connect and test electric brake operation. Secure portable power cables in cable tray with tie

wraps.

If your generator is trailer mounted, pleaseread the towing and safety requirementslisted below.

For more saftey tips, see the trailer safteyguidelines section in this manual.

NOTE



1

NOTE PAGE


Figure 2. Typical Generator Grounding Application

DCA-15SPXU4 — INSTALLATION


1

Outdoor Installation

Install the generator in a area that is free of debris,bystanders, and overhead obstructions. Make sure thegenerator is on secure level ground so that it cannot slide orshift around. Also install the generator in a manner so thatthe exhaust will not be discharged in the direction of nearbyhomes.

The installation site must be relatively free from moistureand dust. All electrical equipment should be protected fromexcessive moisture. Failure to do will result in deteriorationof the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasivematerials have a tendency to cause excessive wear toengine and alternator parts.

Generator Grounding

To guard against electrical shock and possible damage tothe equipment, it is important to provide a good EARTHground.

Article 250 (Grounding) of the National Electrical Code (NEC)provides guide lines for proper grounding and specifies thatthe cable ground shall be connected to the grounding systemof the building as close to the point of cable entry aspractical.

NEC articles 250-64(b) and 250-66 set the followinggrounding requirements:

1. Use one of the following wire types to connect thegenerator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 2) connect theground cable between the lock washer and the nut onthe generator and tighten the nut fully. Connect the otherend of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth groundrod should be buried aminimum of 8 ft. into the ground.

When connecting the generatorto any buildings electricalsystem ALWAYS consult witha licensed electrician.

DCA-15SPXU4 — INSTALLATION

NOTE

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.Whenever an engine is installed indoors the exhaust fumesmust be vented to the outside. The engine should be installedat least two feet from any outside wall. Using an exhaustpipe which is too long or too small can cause excessiveback pressure which will cause the engine to heat excessivelyand possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (suchas concrete) and set firmly on the foundation to isolatevibration of the generator when it is running. The generatormust set at least 6 inches above the floor or grade level (inaccordance to NFPA 110, Chapter 5-4.1). DO NOT removethe metal skids on the bottom of the generator. They are toresist damage to the bottom of the generator and to maintainalignment.

Pay close attention to ventilation when operating thegenerator inside tunnels and caves. The engine exhaustcontains noxious elements. Engine exhaust must be routedto a ventilated area.

CAUTION - EXHAUST HAZARD


DCA-15SPXU4 — GENERAL INFORMATION

DCA-15SPXU4 Whisperwatt™ Series FamiliarizationGeneratorThis MQ Power generator is a 15 kW generator (Figure 3)that is designed as a high quality portable (requires a trailerfor transport) power source for telecom sites, lightingfacilities, power tools, submersible pumps and other industrialand construction machinery.Generator Control PanelThe “Engine Operating Panel” is provided with the following:

■■■■■ Warning Lamp Unit■■■■■ Preheat Lamp■■■■■ Oil Pressure Alarm Lamp■■■■■ Water Temperature Alarm Lamp■■■■■ Battery Charging Alarm Lamp

■■■■■ Speed Control Switch■■■■■ Frequency Meter (Hz)■■■■■ AC Ammeter (Amps)■■■■■ AC Voltmeter (Volts)■■■■■ Voltage Regulator■■■■■ Starter Switch■■■■■ Hour Meter■■■■■ 3-Pole, 70 amp Main Circuit Breaker■■■■■ 1-Pole, 20 amp Circuit Breaker (for GFCI)■■■■■ 1-Pole, 30 amp Circuit Breaker (for L5-30R)■■■■■ 2-Pole, 30 amp Circuit Breaker (for L6-30R)■■■■■ 2-Pole, 50 amp Circuit Breaker (for CS6369)■■■■■ “Control Box” (located behind the Gen. Control Panel)

■■■■■ Automatic Voltage Regulator■■■■■ Current Transformer■■■■■ Over-Current Relay■■■■■ Voltage Rectifer■■■■■ Starter Relay

Output Terminal PanelThe “Output Terminal Panel” is provided with the following:

■■■■■ Three output terminal lugs (1Ø power)■■■■■ 1-Phase Output Terminal■■■■■ 120/240V output receptacle (CS-6369), 50A■■■■■ 120 output receptacle (5-20R)GFCI, 20A■■■■■ 120V output receptacle (L5-30R), 30A■■■■■ 240V output receptacle,(L6- 30R) 30A■■■■■ Ground Terminal (for G.F.C.U)■■■■■ Battery Charger (Optional)■■■■■ Water Heater (Optional)

Open Delta Excitation SystemThe generator is equipped with the state of the art "Open-Delta" excitation system. The open delta system consist ofan electrically independent winding wound among stationarywindings 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 regulatoris supplied from the parallel connections of A to B, A to D,and C to D. These three phases of the voltage input to thevoltage regulator are then rectified and are the excitationcurrent for the exciter section.When a heavy load, such as a motor starting or a shortcircuit occurs, the automatic voltage regulator (AVR)switches the configuration of the open delta to the seriesconnection of B to C. This has the effect of adding the voltagesof each phase to provide higher excitation to the excitersection and thus better voltage response during theapplication of heavy loads.The connections of the AVR to the AC output windings arefor sensing only. No power is required from these windings.The open-delta design provides virtually unlimited excitationcurrent, offering maximum motor starting capabilities. Theexcitation does not have a "fixed ceiling" and respondsaccording the demands of the required load.EngineThe DCA-15SPXU4 is powered by a 4 cylinder, water cooled,Kubota Model V2203-M diesel engine. This engine isdesigned to meet every performance requirement for thegenerator. Reference Table 1 for engine specifications.In keeping with MQ Power's policy of constantly improvingits products, the specifications quoted herein are subject tochange without prior notice.Electric Governor SystemThe electric governor system controls the RPMs of the en-gine. When the engine demand increases or decreases, thegovernor system regulates the frequency variation to ±.25%.Extension CablesWhen electric power is to be provided to various tools orloads at some distance from the generator, extension cordsare normally used. Cables should be sized to allow fordistance in length and amperage so that the voltage dropbetween the generator and point of use (load) is held to aminimum. Use the cable selection chart (Table 6) as a guidefor selecting proper extension cable size.


1

DCA-15SPXU4 — MAJOR COMPONENTS

Figure 3. Major Components

4elbaT . stnenopmoCrojaMrotareneG

.ONMETI NOITPIRCSED

1 ylbmessAretliFriA

2 ylbmessArelffuM

3 ylbmessArotaidaRdnaenignE

4 ylbmessArotareneG

5 ylbmessAyrettaB

6 ylbmessAknaTleuF

7 ylbmessAlenaPlortnoCrotareneG

8 ylbmessAelcatpeceRtuptuO

9 ylbmessAlanimreTtuptuO


Figure 4. Generator Control Panel

DCA-15SPXU4 — GENERATOR CONTROL PANEL

U N V

14

A VHZWATER TEMP. OIL PRESS. BATT. LOW LEVELBATT. LOW LEVEL

DECREASEINCREASE

PREHEAT LAMPPREHEAT LAMP

31 2

7

16

17

18

19

8

6

9

4

5

13 12 11 1015


1

The definitions below describe the controls and functions ofthe Generator Control Panel (Figure 4).

1. Frequency Meter – Indicates the output frequency inhertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the loadis drawing from the generator per leg selected by theammeter phase-selector switch.

3. AC Voltmeter – Indicates the output voltage present atthe U,O, and V Output Terminal Lugs.

4. Engine Warning Lamp Module – This module displaysthe following engine failures:

A. Pre-Heat Lamp – As the engine cranks, this lampwill illuminate to indicate automatic preheating of theengine. When the lamp turns off, the engine has beenpreheated.

B. Water Temperature Alarm Lamp – This lampindicates when the emergency shutdown system hasstopped the engine for abnormally high watertemperature(234 deg. F).

C. Oil Pressure Alarm Lamp – This lamp is on whenthe starter switch is in the “ON” position and the engineoil pressure is low(7.1 PSI). It will indicate when thestarter switch is in the “ON” position, before the enginehas been started, and if the emergency shutdownsystem has stopped the engine.

D. Battery Charging Alarm Lamp – This lamp is ONwhen the output voltage of the alternator drops tob anunusual value. If this lamp indicates during operation,the emergency shutdown system immediately operatesto stop the engine.

5. Hour Meter – Indicates the number of hours machinehas been in use.

6. Engine Speed Control Switch – This switch controlsthe speed of the engine from idle to high.

7. Starter Switch – This switch has four positions.

A. Stop – The switch should be in this position anytimethe unit is not in operation. This position allows removalof the key.

B. Run – The switch should be in this position whenthe unit is in operation.

DCA-15SPXU4 — GENERATOR CONTROL PANEL

C. Preheat – Use this position before starting duringcold weather operating conditions. Observe the PreheatLamp for indication of the proper time for starting theengine.

D. Start – This position starts the engine, and whenreleased will automatically return to the run position.

8. Voltage Regulator Control – Allows ±15% manualadjustment of the generator’s output voltage.

9. CS6369 Receptacle – Provides 240/120 VAC output(50 amps max).

10. L6-30R Receptacle – Provides 240 VAC output (30amps max).

11. L5-30R Receptacle – Provides 120 VAC output (30amps max).

12. GFCI Receptacle – Provides 120 VAC output (20 ampsmax).

13. AC Circuit Breaker - This two-pole, 50A breaker isprovided to protect the CS6369 receptacle from overload.

14. UNV Terminals - Connect load to these terminals ACload for 120/240 VAC single phase 60 Hz. output.

15. GFCI Ground Terminal - Use this terminal to groundthe generator

16. AC Circuit Breaker - This two-pole, 30A breaker isprovided to protect the auxillary receptacle (for L6-30R)from overload.

17. AC Circuit Breaker - This single-pole, 30A breaker isprovided to protect the auxillary receptacle (for L5-30R)from overload.

18. AC Circuit Breaker - This single-pole, 20A GFCI breakeris provided to protect the GFCI receptacle (5-20R) fromoverload.

19. AC Circuit Breaker – This three-pole, 70A main breakeris provided to protect the the U,N, and V OutputTerminal Lugs from overload.


Output Terminal Familiarization

The “Output Terminal Panel ” (Figure 5) is provided with thefollowing:

■■■■■ CS6369 receptacle 125/240V@ 50 amps

■■■■■ Circuit Breaker @ 50 amps (CS6369 receptacle)

■■■■■ 120V GFCI receptacle @ 20 amps

■■■■■ L5-30R receptacle, 125V @ 30 amps

■■■■■ L6-30R receptacle, 240V @ 30 amps

■■■■■ Three Output Terminal Lugs ( U, N, V and Ground)

Output Terminal Panel

The Output Terminal Panel (Figure 5) shown below is locatedon the right-hand side (left from control panel) of the generator.Lift up on the cover to gain access to receptacles and terminallugs.

Figure 5. Output Terminal Panel

DCA-15SPXU4 — OUTPUT TERMINAL PANEL FAMILIARIZATION


1

120 VAC GFCI ReceptacleThis120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptaclecan be used anytime the generator is in operation. Rememberthe load output (current) of the GFCI receptacle is dependenton the load requirements of the U, N, and V output terminallugs.

Pressing the reset button resets the GFCI receptacle afterbeing tripped. Pressing the Test Button (See Figure 6) inthe center of the receptacle will check the GFCI function.Both receptacles should be tested at least once a month.

Figure 6. G.F.C.I. Receptacle

Turn the voltage regulator control knob (Figure 10) on thecontrol panel to obtain the desired voltage. Turning the knobclockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 7. 120/240V CS6369 Twist-LockAuxiliary Receptacle


Twist Lock Dual Voltage 120/240 VAC Receptacle (Option)

There is one CS-6369 120/240V, 50 amp auxilliary twist-lockreceptacle (Figure 7) provided on the output terminal panel.This receptacle is protected by a 50 amp circuit breaker.

Figure 10. Voltage Regulator Control Knob

L5-30R Twist Lock 120 VAC Receptacle

There is one L5-30R, 120 VAC 30 amp auxilliary twist-lockreceptacle (Figure 8) provided on the output terminal panel.

L6-30R Twist Lock 240 VAC Receptacle (Option)

There is one L6-30R, 240 VAC 30 amp auxilliary twist-lockreceptacle (Figure 9) provided on the output terminal panel.

Figure 8. 120 VAC L5-30R Twist-LockAuxiliary Receptacle

Figure 9. 240 VAC L6-30R Twist-LockAuxiliary Receptacle

CS-6369TWIST-LOCKRECEPTACLE

SINGLE-PHASE120/240 VAC

50 AMP OUTPUT


Figure 11. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the OuputTerminal Lugs or the convenience receptacles (Figure 11).Make sure to read the operation manual before attemptingto connect a load to the generator.

To protect the output terminals from overload, a3-pole, 70A main circuit breaker is provided. Make sure toswitch ALL circuit breakers to the OFF position prior tostarting the engine.



1

DCA-15SPXU4 — LOAD APPLICATION/MAXIMUM AMPERAGESingle Phase Load

Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage, frequency,and voltage requirements are satisfactorily supplied by thegenerator for operating the equipment.

Generally, the wattage listed on the nameplate of theequipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, asthe wattage is influenced by the efficiency, power factor andstarting system of the equipment.

Motors and motor-drivenequipment draw much greatercurrent for starting than duringoperation.

When connecting ordinary power tools, a capacity of up tothe generating set’s rated output (kW) multiplied by 0.8 canbe used.

If wattage is not given on theequipment's name plate,approximate wattage may bedetermined by multiplyingnameplate voltage by thenameplate amperage.

The power factor of this generator is 0.8. See Table 5 belowwhen connecting loads.

■■■■■ When connecting a resistance load such as anincandescent lamp or electric heater, a capacity of up tothe generating set’s rated output (kW) can be used.

■■■■■ When connecting a fluorescent or mercury lamp, acapacity 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 currentcapacity.

WATTS = VOLTAGE x AMPERAGE

NOTE

An inadequate size connecting cable which cannot carry therequired load can cause a voltage drop which can burn outthe appliance or tool and overheat the cable. See Table 6.

NOTE

Before connecting this generator to any building’s electricalsystem, a licensed electrician must install an isolation(transfer) switch. Serious damage to the building’selectrical system may occur without this transfer switch.

DANGER - ELECTRICAL SYSTEM HAZARDS

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5 006 0021 .tf005 .tf003 .tf002 .tf521

5.7 009 0081 .tf053 .tf002 .tf521 .tf001

01 0021 0042 .tf052 .tf051 .tf001

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02 0042 0084 .tf521 .tf57 .tf05

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Generator Amperage

Table 7 describes the generator’s current output capability.

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DCA-15SPXU4 — GAUGE READING/ TERMINAL PANEL CONNECTIONSUNV Terminal Output Voltages240/120V output voltages can be obtained using the OutputTerminal Lugs. Use the voltage regulator (VR) to either in-crease or decrease the selected voltage.

Figure 16. Output Terminal Lugs240 VAC Single Phase Connections

2. Turn the voltage regulator knob (Figure 13) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output.

Figure 13. Voltage Regulator Knob (139V/240V)

2. Turn the voltage regulator knob (Figure 13) clockwise toincrease voltage output, turn counterclockwise todecrease voltage output.

1Ø 120 Output Terminal Lug Voltages

1. Connect the load wires to the Output Terminal Lugs asshown in (Figure 12)

Figure 12. Output Terminal Lugs120 VAC Single Phase Connections

Ammeter Gauge.The ammeter gauge (Figure 15) on the generator control panelhas been provided to help observe how much current (amps)is being supplied to the load from the output terminal lugs,GFCI receptacle or any auxulliary receptacles if installed.

Figure 15. AC Ammeter

The ammeter gauge will onlyshow a reading when the OutputTerminal Lugs or auxillaryreceptacles are connected to aload.

NOTE

1Ø 240 Output Terminal Lug Voltages

1. Connect the load wires to the Output Terminal Lugs asshown in (Figure 16)

3. Observe that the output voltage either increases ordecreases by monitoring the voltmeter (Figure 14)reading.

Figure 14. AC Voltmeter


1

DCA-15SPXU4 — SETUP

Figure 17. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil isclean. If the oil is not clean, drain the oil by removing the oildrain plug, and refill with the specified amount of oil as outlinedin the Isuzu Engine Owner's Manual. Oil should be warmbefore draining.

Other types of motor oils may be substituted if they meetthe following requirements:

■■■■■ API Service Classification CC/SC■■■■■ API Service Classification CC/SD■■■■■ API Service Classification CC/SE■■■■■ API Service Classification CC/SF

Circuit Breakers

To protect the generator from an overload, a 3-pole, 70 amp,main circuit breaker is provided to protect the U,N,and VOUTPUT TERMINALs from overload.. In addition a two-pole,50 amp CS6369 circuit breaker is provided to protect theCS6369 receptacle from overload. Make sure to switch ALLcircuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the fillerhole, but DO NOT overfill. Make sure the generator is level.and verify that the oil level is maintained between the twonotches (Figure 17) on the dipstick. See Table 8 for properselection of engine oil.

Figure 18. Internal Fuel Tank System

Refilling the Fuel System

Fuel Check

This generator has an internal fuel tank located inside thetrailer frame and may also be equipped with an optionalenvironmental fuel tank (Figure 18). ALWAYS fill the fueltanks with clean fresh #2 diesel fuel. DO NOT fill the fueltanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishingfuel.The fuel tank cap must be closed tightly after filling.Handle fuel in a safety container. If the container does nothave a spout, use a funnel. Wipe up any spilled fuelimmediately.

ONLY properly trained personel who have read andunderstand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

Fuel spillage on a hot engine can cause a fire or explosion.If fuel spillage occurs, wipe up the spilled fuel completelyto prevent fire hazards. NEVER smoke around or near thegenerator.

DANGER - EXPLOSION/FIRE HAZARDS

-40

-30

-10

-20

-22

-40

-4

-14

032

50

68

86

104

122

10

20

30

40

50

F C

10

W4

0

30

AR

CT

ICO

IL

5W

30

10

W/4

0

15

W3

0

10

W3

0

10

W 20

W4

0

OIL: SAE

Table 8. Recommended Motor Oil

ENVIRONMENTALFUEL TANK(OPTION)

WHISPERWATT15 MQPOWER


DCA-15SPXU4 — SETUPRefueling Procedure:

1. Level Tanks – Make sure fuel cells are level with theground. Failure to do so will cause fuel to spill from thetank before reaching full capacity (Figure 19).

Figure 19. Only Fill on Level Ground

ONLY! use #2 diesel fuel whenrefueling.

NOTE

3. NEVER overfill fuel tank – It is important to read thefuel gauge when filling trailer fuel tank. DO NOT wait forfuel to rise in filler neck (Figure 21).

Figure 21. Full Fuel Tank

Figure 22. Fuel Expansion

2. Remove fuel cap (internal fuel tank) and fill fuel tankas shown Figure 20.

ALWAYS place trailer on firm level ground before refuelingto prevent spilling and maximize the amount of fuel thatcan be pumped into the tank.


Diesel fuel and its vapors are dangerousto your health and the surroundingenvironment. Avoid skin contact and/orinhaling fumes.

WARNING - RESPIRATORY HAZARDS

DO NOT OVER-FILL fuel system. Leave room for fuelexpansion. Fuel expands when heated (Figure 22).


Figure 20. Fueling the Generator

If generator is equipped with anenvironmental fuel tank, referenceFigures 21 and 22.

NOTE


1

Coolant (Antifreeze/Summer Coolant/Water)KUBOTA recommends antifreeze/summer coolant for use intheir engines, which can be purchased in concentrate (andmixed with 50% demineralized water) or pre-diluted. Seethe KUBOTA Engine Owner's Manual for further details.

Day-to-day addition of coolant is done from the recoverytank. When adding coolant to the radiator, DO NOT removethe radiator cap until the unit has completely cooled. SeeTable 9 for engine, radiator, and recovery tank coolantcapacities. Make sure the coolant level in the recovery tankis always between the "H" and the "L" markings.

Operation Freezing Weather

When operating in freezing weather, be certain the properamount of antifreeze (Table 10) has been added.

Cleaning the Radiator

The engine may overheat if the radiator fins becomeoverloaded with dust or debris. Periodically clean the radiatorfins with compressed air. Cleaning inside the machine isdangerous, so clean only with the engine turned off and thenegative battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it inaccordance with the KUBOTA Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or toinsufficient charging of the battery. Inspect the fan belt fordamage and wear and adjust it in accordance with theKUBOTA Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15mm (Figure 23) when depressed with the thumb as shownbelow.

Figure 23. Fan Belt Tension

DCA-15SPXU4 — SETUP

When the antifreeze is mixed withwater, the antifreeze mixing ratiomust be less than 50%.

NOTE

If adding coolant/antifreeze mix to theradiator, DO NOT remove the radiator capuntil the unit has completely cooled. Thepossibility of hot! coolant exists whichcan cause severe burns.


NEVER place handsnear the belts or fanwhile the generator setis running.

CAUTION - ROTATING PARTS

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DCA-15SPXU4 — SETUPWhen connecting battery do the following:

1. NEVER connect the battery cables to the batteryterminals when the ignition switch is in the ON position

2. Place a small amount of battery terminal treatmentcompound around both battery terminals. This will ensurea good connection and will help prevent corrosion aroundthe battery terminals.

Figure 24. Battery Connections

ALWAYS disconnect the negative terminal FIRST andreconnect negative terminal LAST.

Inadequate battery connections may cause poor startingof the generator, and create other malfunctions.

Alternator

The polarity of the alternator is negative grounding type. Whenan inverted circuit connection takes place, the circuit will bein short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of waterinto the alternator can cause corrision and damage thealternator.

Wiring

Inspect the entire generator for bad or worn electrical wiringor 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 forwear and tightness. Tighten all hose clamps and check hosesfor leaks.

If any hose (fuel or oil) lines are defective replace themimmediately.

If the battery cable is connectedincorrectly, electrical damage to thegenerator will occur. Pay closeattention to the polarity of thebattery when connecting thebattery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.Always maintain battery fluid level between the specifiedmarks. Battery life will be shortened, if the fluid level are notproperly maintained. Add only distilled water whenreplenishment is necessary.

DO NOT over fill. Check to see whether the battery cablesare loose. Poor contact may result in poor starting ormalfunctions. Always keep the terminals firmly tightened.Coating the terminals with an approved battery terminaltreatment compound. Replace battery with onlyrecommended type battery.

The battery is sufficiently charged if the specific gravity ofthe battery fluid is 1.28 (at 68° F). If the specific gravityshould fall to 1.245 or lower, it indicates that the battery isdead 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 24) are properlyconnected to the battery terminals as shown below. The RedCable is connected to the positive terminal of the battery,and the Black Cable is connected to the negative terminalof the battery.

CAUTION - BATTERY SERVICING SAFETY

CAUTION - BATTERY SERVICING SAFETY


1

DCA-15SPXU4 — GENERATOR START-UP PROCEDURE

The engine's exhaust contains harmful emissions.ALWAYS have adequate ventilation when operating.Direct exhaust away from nearby personnel.

Before Starting

1. Place the main, G.F.C.I., and aux. circuit breakers(Figure 25) in the OFF position prior to starting the engine.

2. Connect the load to the receptacles or the outputterminal lugs as shown in Figure 11. These loadconnection points can be found on the output terminalpanel and the output terminal panel’s hard wire hookuppanel.

3. Tighten terminal nuts securely to prevent load wires fromslipping out.

4. Close all engine enclosure doors (Figure 26).

CAUTION - LETHAL EXHAUST HAZARD

NEVER! manually start the engine with the main, GFCIor auxiliary circuit breakers in the ON (closed) position.

WARNING - STARTING THE GENERATOR

Figure 26. Engine Enclosure Doors Figure 29. Frequency Meter (Hz)

3. Once the engine starts, let it engine run for 1-2 minutes.Listen for any abnormal noises. If any abnormalitiesexists shutdown the engine and correct the problem.

4. The generator's frequency meter (Figure 29) should bedisplaying the 60 cycle output frequency in HERTZ.

Figure 28. Ignition Switch

STOP

PRE-HEATRUN

START

B

STOP

PRE-HEAT

RUN

START

A

Figure 25. Main, GFCI, and AuxillaryCircuit Breakers (OFF)

Start-up Procedure

1. Set the Speed Control Switch to the START/IDLE position(Figure 27).

2. Insert the ignition key into the ignition switch. Turn thekey clockwise to the PRE-HEAT position (Figure 28A)and observe the Pre-Heat Lamp. When the Pre-HeatLamp has turned off, continue turning the ignition keyclockwise to the START position (Figure 28B). When theengine starts, release the key. If engine fails to startwithin 10 seconds, wait 30 seconds and repeat this step.

Figure 27. Speed Control Switch (START/IDLE)


DCA-15SPXU4 — GENERATOR START-UP PROCEDURE

Figure 33. Voltage Adjust Control Knob

7. The generator's AC-voltmeter (Figure 32) will display thegenerator’s output in VOLTS. If the voltage is not withinthe specified tolerance, use the voltage adjustmentcontrol knob (Figure 33) to increase or decrease thedesired voltage.

Figure 32. Voltmeter

8. Place the main, GFCI, and aux. circuit breakers in theON position (Figure 34).

9. Observe the generator's ammeter (Figure 35) and verifyit reads the anticipated amount of current with respectto the load. The ammeter will only display a currentreading if a load is in use.

Figure 35. Ammeter (Load)10. The generator will run until manually stopped or an

abnormal condition occurs.

Figure 31. Ammeter (No Load)

6. The ammeter (Figure 31) will indicate zero amps withno load applied. When a load is applied, the ammeterwill indicate the amount of current that the load isdrawing from the generator.

5. Set the Speed Control Switch to the RUN position(Figure 30).

Figure 30. Speed Control Switch (RUN)

Figure 34. Main, GFCI, and Aux.Circuit Breakers (ON)


1

DCA-15SPXU4 — GENERATOR SHUT-DOWN PROCEDURES

NEVER stop the engine suddenly except in an emergency.

WARNING - SHUTTING DOWN THE GENERATOR

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the main, GFCI, and aux. circuit breakersas shown in Figure 25 to the OFF position.

2. Set the Speed Control Switch to the START/IDLE positionas shown in Figure 27 and let the engine cool for 3-5minutes with no load applied.

3. Turn the ignition key counter-clockwise to the STOPposition. When the engine has stopped, remove key.Place key in a safe place where it will not be lost.

4. Inspect entire generator for any damage or loosening ofcomponents that may have occured during operation.

Emergency Shutdown Procedure

1. Turn the ignition key counter-clockwise to the STOPposition. When the engine has stopped, remove key.Place key in a safe place where it will not be lost.

2. Place both the main, GFCI, and aux. circuit breakersas shown in Figure 25 to the OFF position.


DCA-15SPXU4 — MAINTENANCE

Service Daily

If the engine is operating in very dusty or dry grassconditions, a clogged air cleaner will result. This can lead toa loss of power, excessive carbon buildup in the combustionchamber and high fuel consumption. Change air cleanermore frequently if these conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to seasonand locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulatein the bottom of the tank. Occasionally inspect the fueltank for water contamination and drain the contents ifrequired.

During cold weather, the more empty volume inside thetank, the easier it is for water to condense. This can bereduced by keeping the tank full with diesel fuel.

General Inspection

Prior to each use, the generator should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuel,oil, and coolant leaks. Use Table 11 as a general enginemaintenance guideline (Refer to the Engine InstructionManual).

Air Cleaner

Every 250 hours: Remove air cleaner element and clean theheavy duty paper element with light spray of compressedair. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator (If Equipped)

This indicator is attached to the air cleaner. When the aircleaner element is clogged, air intake restriction becomesgreater and the dust indicator signal shows RED meaningthe element needs changing or service. After changing theair element, press the dust indicator button to reset theindicator.

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ENIGNE

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1


Generator Storage

For longe term storage of the generator the following isrecommended:

Fill the fuel tank completely. Treat with a fuel stabilizerif necessary.

Completely drain the oil from the crankcase and refill ifnecessary with fresh oil.

Clean the entire generator, internal and external.

Cover the generating set and store in a clean, dry place.

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up andplace on blocks so tires do not touch the ground or blockand completely remove the tires.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and atthe lower part of the radiator and drain coolant. Open theradiator cap while draining. Remove the overflow tankand drain.

Check hoses for softening and kinks. Check clamps forsigns of leakage.

Flush the radiator by running clean tap water throughradiator until signs of rust and dirt are removed. DO NOTclean radiator core with any objects, such as ascrewdriver.

Tighten both cocks and replace the overflow tank.

Replace with coolant as recommended by the enginemanufaturer.

Close radiator cap tightly.

Air Removal

If air enters the fuel injection system of a diesel engine,starting becomes impossible. After running out of fuel, orafter disassembling the fuel system, bleed the systemaccording to the following procedure. See the KUBOTAEngine Manual for details.

To restart after running out of fuel, turn the switch to the“ON” position for 15-30 seconds. Try again, if needed. Thisunit is equipped with an automatic air bleeding system.

Check Oil Level

Check the crankcase oil level prior to each use, or when thefuel tank is filled. Insufficient oil may cause severe damageto the engine. Make sure the generator is level. The oil levelmust be between the two notches on the dipstick as shownin Figure 17.

Replacing Oil Filter

Remove the old oil filter.

Apply a film of oil to the gasket on the new oil filter.

Install the new oil filter.

After the oil cartridge has been replaced, the engine oilwill drop slightly. Run the engine for a while and checkfor leaks before adding more oil if needed. Cleanexcessive oil from engine.

Allow engine to cool when flushing outradiator. Flushing the radiator while hotcould cause serious burns from water orsteam.


Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500hours or so.

Loosen the drain plug at the lower top of the fuel filter.Drain the fuel in the fuel body together with the mixedwater. DO NOT spill the fuel during disassembly.

Vent any air.

Cleaning the Fuel StrainerClean the fuel strainer if it contains dust or water. Removedust or water in the strainer cap and wash it in gasoline.Securely fasten the fuel strainer cap so that fuel will notleak. Check the fuel strainer every 200 hours of operation oronce a month.



To ensure adequate startingcapability, always have powerapplied to the generator'sinternal battery charger.

NOTE

Figure 36. Battery Charger &Jacket Water Heater Power Connections

Jacket Water Heater and Internal Battery Charger120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,20 amp input receptacles located on the output terminalpanel.

The purpose of these receptacles is to provide power viacommercial power to the jacket water heater and internalbattery charger.

These receptacles will ONLY function when commercialpower has been supplied to them (Figure 36). To applycommercial power to these receptacles, a power cord ofadequate size will be required (See Table 6).

When using the generator in hot climates there is no reasonto apply power to jacket water heater. However, if thegenerator will be used in cold climates it is always a goodidea to apply power to the jacket water heater at all times. Toapply power to the jacket water heater simply apply power tothe jacket water heater receptacle via commercial powerusing an power cord of adequate size.

If the generator will be used daily, the battery should normallynot require charging. If the generator will be idle (not used)for long periods of time, apply power to the battery chargerreceptacle via commercial power using an power cord ofadequate size.


1

DCA-15SPXU4 — TRAILER MAINTENANCEHydraulic Surge BrakesHydraulic surge brakes (Figure 37) should not require anyspecial attention with the exception of routine maintenancesuch as shoe and lining replacement. Brake lines should beperiodically checked for cracks, kinks, or blockage.

Figure 37. Hydraulic Brake Components

BrakesTrailer brakes should be inspected the first 200 miles ofoperation. This will allow the brake shoes and drums to seatproperly. After the first 200 mile interval, inspect the brakesevery 3,000 miles. If driving over rough terrain, inspect thebrakes more frequently.

Figure 37 displays the major hydraulic surge brakecomponents that will require inspection and maintenance.Please inspect these components as required using steps 1through 8 and Table 12 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jackstands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slotat the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate thestar wheel of the adjuster assembly to expand the brakeshoes.

5. Adjust the brake shoes outward until the pressure of thelining against the wheel drum makes the wheel difficultto turn.

6. Adjust, rotate the star wheel in the opposite directionuntil the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer tothe ground.

8. Repeat steps 1 through 7 on the remaining brakes.

ActuatorHydraulic surge braking requires the installation of an actuatorat the tongue of the trailer. Remember the surge or push ofthe trailer toward the tow vehicle automatically synchronizesthe trailer brakes with the tow vehicle brakes. As the trailerpushes against the tow vehicle the actuator telescopestogether and applies force to the master cylinder, supplyinghydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to makesure that it is functioning correctly. Never use an undersizeactuator.

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Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproperly matched.

Tire Wear/InflationTire inflation pressure is the most important factor in tire life.Pressure should be checked cold before operation DO NOTbleed air from tires when they are hot!. Check inflationpressure weekly during use to insure the maximum tire lifeand tread wear.

Table 13 (Tire Wear Troubleshooting) will help pinpoint thecauses and solutions of tire wear problems.

SuspensionThe leaf suspension springs and associated components(Figure 38) should be visually inspected every 6,000 milesfor signs of excessive wear, elongation of bolt holes, andloosening of fasteners. Replace all damaged parts(suspension) immediately. Torqued suspension componentsas detailed in Table 14.

Figure 38. Major Suspension Components

DCA-15SPXU4 — TRAILER MAINTENANCE

DO NOT attempt to repair or modify a wheel. DO NOTinstall in inner tube to correct a leak through the rim. If therim is cracked, the air pressure in the innertube may cause pieces of the rim toexplode (break off) with great force andcause serious eye or bodily injury.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS wear safety glasses whenremoving or installing force fitted parts.Failure to comply may result in seriousinjury.

CAUTION - EYESIGHT HAZARD

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TLOB-U"8/3 53-XAM03-NIM



SHACKLE BOLT

SPRING EYE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT-BOLT ASSEMBLY.

SHOULDER TYPE

SHACKLE BOLT05-XAM03-NIM


1

NEVER use an pneumatic airgun to tighten wheel lug nuts.

Figure 39. Wheel Lug NutsTightening Sequence

DCA-15SPXU4 — TRAILER MAINTENANCE

NOTE

Lug Nut Torque RequirementsIt is extremely important to apply and maintain proper wheelmounting torque on the trailer. Be sure to use only thefasteners matched to the cone angle of the wheel. Properprocedure 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 39). DO NOTtorque the wheel lug nuts all the way down. Tighten eachlug nut in 3 separate passes as defined by Table 15.

3. After first road use, retorque all lug nuts in sequence.Check all wheel lug nuts periodically.

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"31 52-02 04-53 56-05

"41 52-02 06-05 021-09

"51 52-02 06-05 021-09

"61 52-02 06-05 021-09


DCA-15SPXU4 — GENERATOR WIRING DIAGRAM

Figure 40. Generator Wiring Diagram


1

DCA-15SPXU4 — ENGINE WIRING DIAGRAM

Figure 41. Engine Wiring Diagram


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DCA-15SPXU4 — TROUBLESHOOTING (ENGINE)Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of abreakdown, use Table 16 shown below for diagnosis of the engine. If the problem cannot be remedied, consult our company'sbusiness office or service plant.


1

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DCA-15SPXU4 — TROUBLESHOOTING (ENGINE)


Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of abreakdown, use Table 17 shown below for diagnosis of the generator. If the problem cannot be remedied, consult ourcompany's business office or service plant.

DCA-15SPXU4 — TROUBLESHOOTING (GENERATOR)

GNITOOHSELBUORTROTARENEG.71ELBAT


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1

DCA-10SPX4 — TROUBLESHOOTING (PRE-HEAT LAMP CODES)

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When the Emergency/Malfunction Diagnosis Function has been activated, it stops the engine and flashes the pre-heatlamp to indicate the cause of the malfunction with its flashing patterns. The flashing patterns and countermeasures areshown below. The patterns consist of combinations of one or more long flashes and one or more short flashes.

PARTS AND OPERATION MANUALOPERATION MANUAL

Your Local Dealer is:

HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATESMultiquip Corporate Offi ce MQ Parts Department

18910 Wilmington Ave.Carson, CA 90746 Contact: [email protected]

Tel. (800) 421-1244Fax (800) 537-3927

800-427-1244310-537-3700

Fax: 800-672-7877Fax: 310-637-3284

Service Department Warranty Department

800-421-1244310-537-3700

Fax: 310-537-4259 800-421-1244310-537-3700

Fax: 310-537-1173

Technical Assistance

800-478-1244 Fax: 310-943-2238

MEXICO UNITED KINGDOM

MQ Cipsa Multiquip (UK) Limited Head Offi ce

Carr. Fed. Mexico-Puebla KM 126.5Momoxpan, Cholula, Puebla 72760 MexicoContact: [email protected]

Tel: (52) 222-225-9900Fax: (52) 222-285-0420

Unit 2, Northpoint Industrial Estate, Globe Lane,Dukinfi eld, Cheshire SK16 4UJContact: [email protected]

Tel: 0161 339 2223Fax: 0161 339 3226

CANADA

Multiquip

4110 Industriel Boul.Laval, Quebec, Canada H7L 6V3Contact: [email protected]

Tel: (450) 625-2244Tel: (877) 963-4411Fax: (450) 625-8664

© COPYRIGHT 2011, MULTIQUIP INC.

Multiquip Inc and the MQ 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 inthis 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.

Documents

WHISPERWATT SERIES MODEL DCA-15SPXU4service.multiquip.com/pdfs/DCA15SPXU4-rev-0-manual.pdf · WHISPERWATTTM SERIES MODEL DCA-15SPXU4 60 Hz GENERATOR. ... Model KUBOTA V2203-M Type