MQ Power DCA40SSKU4F2 Operation Manual

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Page 1

OPERATION MANUAL

MODEL DCA40SSKU4F2

60Hz Whisperwatt™ Generator

(KUBOTA V2403-CR-TIE4BG DIESEL ENGINE)

Revision #0 (07/20/17)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Page 2

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 3

REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafﬁc Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator

NHTSA

1200 New Jersey Avenue S.E.

Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 3

Page 4

DCA40SSKU4F2 60 Hz Generator

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

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

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

Nameplate/Safety Information ................................. 5

Safety Information .............................................. 6-12

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

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

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

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

Engine Control Panel ........................................ 18-19

Generator Control Panel ........................................ 20

Output Terminal Panel Familiarization .............. 21-23

Load Application .................................................... 24

Generator Outputs ................................................. 25

Generator Outputs/Gauge Reading ....................... 26

Output Terminal Panel Connections ................. 27-28

Inspection/Setup ............................................... 29-32

Generator Start-Up Procedure (Manual) ......... 33-36

Generator Shut-Down Procedures ........................ 37

Maintenance ..................................................... 38-45

Troubleshooting Diagnostics ................................. 46

Troubleshooting (Generator/Engine) ..................... 47

Generator Wiring Diagram ..................................... 48

Engine Wiring Diagram .......................................... 49

Battery Charger Wiring Diagram ........................... 50

Engine Block Heater Wiring Diagram .................... 51

TABLE OF CONTENTS

NOTICE

Speciﬁcations are subject to change without notice.

PAGE 4 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 5

NAMEPLATE/SAFETY INFORMATION

Operation of this equipment may create sparks that can start fires around dry vegetation.

A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

M9504200004

ENVIRONMENTAL WARNING

This unit is designed to contain operating fluids only. The environmental containment is not designed to control fluids from an external source. It is the operator’s responsibility to monitor fluid levels at all times.

DO NOT EXCEED THE RECOMMENDED

MAXIMUM CAPACITY

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison gas you cannot see or smell.

NEUTRAL BONDED TO FRAME

120V

120 V

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

NEVER use inside a home

or garage. Even if doors and windows are open.

WARNING

MOVING PARTS can cause severe injury. DO NOT operate with doors open.

Stop engine before servicing.

FAN SHROUD

ARC FLASH AND SHOCK HAZARD Appropriate PPE Required

Appropriate Personal Protection Equipment and Tools Required when working on this equipment.

M91010030

DANGER

NEUTRAL BONDED TO FRAME

120V

120 V

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

ONLY use OUTSIDE and far away from windows, doors, and vents.

Avoid other generator hazards. READ MANUAL BEFORE USE.

M9503000004

WARNING

NEUTRAL BONDED TO FRAME

120V

120 V

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

M90320010

TOP VIEW

M92010070

WARNING

HOT COOLANT can cause

severe burns.

Do not remove cap if radiator is hot.

M91020000

FRONT VIEW

M90310000

CAUTION

Maximum capacity of lifting

bail is 5,150 lbs.

WARNING

ELECTRIC SHOCK HAZARD

Do not touch internal wiring or connections while this machine is operating.

Turn power off before servicing.

M92010000

M15000150

ECU

Intergrated Gauge Control

Low Oil Pressre

High temp.

Over Crank

Over Speed

Engine Started

CAUTION

Stop engine before switching.

M90130000

CONTROL BOX

(Right-Side)

V-W

W-U

U-V

OFF

DECREASE

INCREASE

CAUTION

This machine stops and starts automatically and without notice.

M92010060

WARNING

ENGINE EXHAUST can cause severe injury or death.

Use only in open, well ventilated areas or vent exhaust outside.

M9503200004

CAUTION

HOT PARTS can burn skin.

DO NOT touch until the

machine has sufficiently cooled.

M91010000

DANGER

HIGH VOLTAGE

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 5

M92010040

WARNING

ELECTRIC SHOCK HAZARD

Do not touch output terminals while this machine is operating. Turn power off before servicing.

WARNING

ELECTRIC SHOCK HAZARD Always complete the grounding path from the ground terminal on the genset to an external grounding source.

See instruction manual for details.

SIDE VIEW

WARNING

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

M92010050

CAUTION

DO NOT disconnect the Battery Cables

after shutting down the engine for

at least 30 seconds

M90130000

This machine stops and starts automatically and without notice.

CAUTION

SIDE VIEW

M92010060

Page 6

SAFETY INFORMATION

DO NOT operate or service the generator before reading the entire manual. Safety precautions should be followed at all times when operating this generator. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

SAFETY SYMBOLS

Potential hazards associated with the operation of this generator will be referenced with hazard symbols which may appear throughout this manual in conjunction with

safety messages.

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.

or NOTICE.

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 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 7

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this generator. Damage

Also, know the

and

This information will be invaluable in

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

lubricate components or attempt service on a

keep the generator in proper running condition.

Fix damage to generator and replace any broken parts

store generator properly when it is not being used. Generator should be stored in a clean, dry location out of the reach of children and unauthorized personnel.

CAUTION

NEVER operate this generator 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 generator when not

feeling well due to fatigue, illness or when under medication.

NEVER operate this generator under the inﬂ uence of

drugs or alcohol.

ALWAYS check the generator for loosened threads or bolts before starting.

DO NOT use the generator for any purpose other than

its intended purposes or applications.

to the generator and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the generator in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This generator should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to generator modiﬁ cations. Unauthorized generator modiﬁ cation will void all warranties.

 NEVER disconnect any

devices will void all warranties.

CAUTION

 NEVER

running machine.

NOTICE

 ALWAYS ensure generator is on level ground before use.

 ALWAYS



immediately.

 ALWAYS

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 7

Page 8

ENGINE SAFETY



NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

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 sufﬁ cient 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

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

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

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 ﬂ ames from the engine exhaust. Spark arresters are qualiﬁ ed 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

SAFETY INFORMATION

DANGER

The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine in this generator

requires an adequate free ﬂ ow of cooling air. NEVER operate this generator in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the generator 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 ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage to the engine or generator can result if operating in speed ranges above the maximum allowable.



the operating performance.

In order for a diesel engine to operate at peak efﬁ ciency,

to completely burn all of the fuel.

DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

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,

mufﬂ er or cylinder. Allow these parts to cool before servicing generator.

hours to burn off the accumulated unburned fuel.



local Health and Safety Administrator.

PAGE 8 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 9

FUEL SAFETY



ELECTRICAL SAFETY



 Backfeed to a utility system can cause electrocution

codes. Failure to do so could result in electrical shock or

while AC power from the

cables or cords when

connecting generator to generator. Inspect for cuts in the

connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

DO NOT start the engine near spilled fuel or combustible ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from sparks and open ﬂ ames.

ALWAYS use extreme caution when working with

ﬂ ammable liquids.

DANGER

SAFETY INFORMATION

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

burn, causing serious injury or even death.

Power Cord/Cable Safety

DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated areas and away from sparks and ﬂ ames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the

generator. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

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.

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water

generator is being transferred to a load.

 NEVER use damaged or worn

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

damage to the generator.

NOTICE

 ALWAYS

Chart in this manual.

NEVER insert any objects into the output

receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution

or death.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 9

Page 10

SAFETY INFORMATION

Grounding Safety



BATTERY SAFETY

keep the battery charged. If the battery is not

recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration

If the battery liquid (dilute sulfuric acid) comes into

, rinse skin or clothing

If the battery liquid (dilute sulfuric acid) comes into

, rinse eyes immediately with plenty

of water and contact the nearest doctor or hospital to

NEGATIVE battery terminal

keep battery cables in good working condition.

WARNING

DANGER

This generator is equipped with a grounding terminal

attached to the enclosure. Electrical grounding requirements can differ by State, Province, District,

Municipality, and unique application settings.

For portable and vehicle-mounted generators, Multiquip

recognizes the guidance provided in NEC Handbook Article 250.34 Parts A and B, and 29 CFR 1926.404 (f) (3) (i). If a more deﬁ nitive earth-to-ground safeguard is required, please consult a qualiﬁ ed electrician and reference appropriate National Electrical Code (NEC) guidelines in establishing an exterior grounding point

generator.

NEVER use gas piping as an electrical ground.

NOTICE

There is a permanent conductor bond between generator (stator winding) and the frame.

DANGER

DO NOT drop the battery. There is a possibility that the

battery will explode.

DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

 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

charged, combustible gas will build up.

 ALWAYS

of combustible gasses.



contact with clothing or skin immediately with plenty of water.



contact with eyes

seek medical attention.

CAUTION

 ALWAYS disconnect the

before performing service on the generator.

 ALWAYS

Repair or replace all worn cables.

PAGE 10 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 11

SAFETY INFORMATION

ENVIRONMENTAL SAFETY/DECOMMISSIONING

Decommissioning is a controlled process used to safely retire a piece of generator that is no longer serviceable. If the generator 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.

EMISSIONS INFORMATION

The diesel engine used in this generator has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained

This engine has been certiﬁ ed to meet US EPA Evaporative

Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the generator or create an unsafe

Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in ﬁ nes or other penalties.

The emission control label is an integral part of the emission

If a replacement emission label is needed, please contact

NOTICE

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 generator.

When the life cycle of this generator is over, remove

battery(s) and bring to an appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.

When the life cycle of this generator is over, it is

recommended that the generator 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.

NOTICE

in diesel exhaust emissions.

emissions requirements in the installed conﬁ guration.

condition.

Emission Control Label

system and is strictly controlled by regulations.

The label must remain with the engine for its entire life.

your authorized engine distributor.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 11

Page 12

Table 1. Generator Speciﬁcations

Model

Type

Armature Connection Star with Neutral Zigzag

Phase

Standby Output

Prime Output

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 240/139

3Ø Voltage (L-L/L-N)

Voltage Selector Switch at 3Ø 480/277

1Ø Voltage (L-L/L-N)

Voltage Selector Switch at 1Ø 240/120

Power Factor

Frequency

Speed

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Table 2. Engine Speciﬁcations

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Engine Oil Type

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

SPECIFICATIONS

DCA-40SSKU4F2

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

3 Single

30.2 KW (37.8 kVA) 27.3 KW

28.8 KW (36 kVA) 26 KW

208Y/120, 220Y/127,

240Y/139

416Y/240, 440Y/254,

480Y/277

N/A 240/120

0.8 1.0

60 Hz

1800 rpm

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

2,205 lbs. (1,000 kg)

2,735 lbs. (1,240 kg)

Kubota V2403-CR-TIE4BG, Tier 4 Final Certiﬁed

4-cycle, water cooled, direct injection, turbocharged,

EGR, ECM, and DOC

4 cylinders

3.42 x 4.01 in. (87 x 102 mm)

149 in

(2.43 liters)

48.3 HP at 1800 rpm

Electric

2.77 gal. (10.5 liters)

2.56 gal. (9.7 liters)

API service class CJ-4 or JASO DH-2

Ultra Low Sulfer No. 2 Diesel Fuel

67.4 gal. (255 liters)

2.3 gal. (8.7 L)/hr at full load 1.8 gal. (6.7 L)/hr at 3/4 load

1.3 gal. (5.1 L)/hr at 1/2 load 0.8 gal. (3.0 L)/hr at 1/4 load

27 (CCA 0° 800A) x 1

N/A

PAGE 12 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 13

DIMENSIONS

TOP VIEW

A E

MAXIMUM

LIFTING POINT

5,150 LBS. (2,315 KG)

SIDE VIEW

FRONT VIEW

M91020000

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 24.88 (632) E 25.51 (648)

B 24.88 (632) F 76.38 (1,940)

C 25.51 (648) G 53.15 (1,350)

D 32.28 (820) H 37.40 (950)

Dimension in. (mm) Reference Letter Dimension in. (mm)

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 13

Page 14

GENERATOR

./2.4 M (MINIMUM)

GROUND LUG

GROUND CABLE

INSTALLATION

IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD.

REFERENCE

NEC 250

8 FT

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 15

INSTALLATION

OUTDOOR INSTALLATION

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.

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.

GENERATOR GROUNDING

NOTICE

The Occupational Safety and Health Administration (OSHA) and the National Electrical Code (NEC) recommend that if the generator is providing electrical power to a structure (home, ofﬁce shop, trailer or similar) it must be connected to a grounding electrode system, such a driven ground rod (Figure 2).

if applicable ,to guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground, (Figure 2).

NOTICE

ALWAYS check with State, Province, District and Municipalities for electrical grounding requirements before using generator.

Article 250 (Grounding) of the NEC handbook provides guidelines 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.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set ﬁrmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the ﬂoor or grade level (in accordance to NFPA 110, Chapter 54.1). 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.

NEC article 250 specifices the following grounding requirements:

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

a. Copper 10 AWG (5.3 mm

b. Aluminum 8 AWG (8.4 mm

) or larger.

2. When grounding of the generator (Figure 2) is required, connect one end the ground cable to the ground lug on the generator. Connect the other end of the ground cable to the ground rod (earth ground).

3. NEC article 250 speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 15

Page 16

GENERAL INFORMATION

GENERATOR

This MQ Power generator (Figure 3) is 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.

ENGINE CONTROL PANEL

The “Engine Operating Panel” is provided with the following:

 Engine Warning Lamp Module

• Engine Shutdown LED

• Engine Pre-Alarm LED

• Charging Battery LED

• Pre-Heat LED

• Fuel Filter Water Level LED

• Fuel Leak Detected LED

 Fuel Gauge  Auto-Start Controller  Hour Meter  Speed Control Switch  Auto Start Switch  Diagnostic Switch  Emergency Stop Button (Optional)

GENERATOR CONTROL PANEL

The “Generator Control Panel” is provided with the following:

 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltage Regulator  3-Pole, 110 amp Main Circuit Breaker  “Control Box” (Located Behind Eng/Gen Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

• Voltage Selector Switch

OUTPUT TERMINAL PANEL

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

 Two 250 VAC output receptacles (CS-6369), 50 amps  Two auxiliary circuit breakers, 250V @50 amps  Two 125 VAC output receptacles, (GFCI), 20 amps  Two duplex circuit breakers, 125V@ 20 amps  Five output terminal lugs (3Ø power)

OPTIONS

 Battery Charger  Water Heater  Low Coolant Level Switch/Indicator  Camlock Connectors  Emergency Stop Switch

OPEN DELTA EXCITATION SYSTEM

This 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.

ENGINE

This generator unit incorporates a Kubota V2403-CR-TIE4BG 4-cycle water cooled, direct injection turbocharged 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%.

PAGE 16 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 17

MAJOR COMPONENTS

3 PHASE 240/139

3 PHASE

1 PHASE

480/277

240/120

PRESSTO LOCK

UVWO

TOP VIEW

FRONT VIEW

Figure 3. Major Components

SIDE VIEW

Table 4. Generator Major Components

Intergrated Gauge Control

ECU

Low Oil Pressre

OFF/RESET

High temp.

PRESSURE

HIGH COOLANT

Over Crank

ENGINE RUNNING

Over Speed

Engine Started

V-W

U-V

W-U

OFF

DECREASEINCREASE

M91020000

ITEM NO. DESCRIPTION

1 Voltage Selector Switch Assembly

2 Air Cleaner Assembly

3 Mufﬂer Assembly

4 Fuel Tank Assembly

5 Fuel Drain Plug

6 Engine/Radiator Assembly

7 Coolant Drain Plug

8 Output Terminal Panel Assembly

9 Generator Assembly

10 Lifting Hook

11 Battery

12 Engine Control Panel Assembly

13 Generator Control Panel Assembly

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 17

Page 18

DECREASE

INCREASE

V-W

U-V

OFF

W-U

Low Oil Pressre

High temp.

Over Crank

Over Speed

Engine Started

ECU

Intergrated Gauge Control

ENGINE CONTROL PANEL

Figure 4. Engine Control Panel

The deﬁnitions below and on the preceeding page describe the controls and functions of the Engine Control Panel (Figure 4).

1. Engine Warning LEDs — There are six engine

warning lamps, they are deﬁned as follows:

a. Engine Shutdown — Indicates that the engine

has shutdown due to an engine failure LED will turn on.

b. Engine Pre Alarm LED — Indicates that an engine

failure has occured. LED will turn on or blink.

c. Battery Charge Alarm LED — This LED is ON

when the output voltage of the alternator drops below a set value. If this lamp is ON during normal operation, the emergency shutdown system will immediately stop the engine.

d. Fuel Filter Water Level LED — This LED is ON

when the water level in the fuel ﬁlter is extradinary high.

e. Fuel Leak Detected Lamp LED — This LED is

ON when theﬂuid in the containment is higher than allowable level.

f. Pre-Heat LED — The pre-heat LED will be

ON during the pre-heating cycle (cold weather conditions). When the pre-heat cycle is completed the LED will turn OFF and the engine can be started.

PAGE 18 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 19

ENGINE CONTROL PANEL

2. Auto START/STOP Engine Controller (CAN 77) —

This controller has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault) has been detected. When a fault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator. During cranking cycle, the ECU will attempt to crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third

attempt, the engine will be shutdown by the engine controller’s Over Crank Protection mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the Over Speed Protection mode.

Also the engine controller will shut down the engine in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

A. Low Oil Pressure — Indicates the engine pressure

has fallen below 14.2 psi (98 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault and the engine will be shut down.

3. Fuel Guage – Indicates amount of diesel fuel available.

4. Hour Meter – Indicates amount of time generator has been in use.

5. Auto Start Stop Switch – This switch controls the running of the unit. If this switch is set to the OFF/ RESET position, the unit will not run. When this switch is set to the manual position, the generator will start immediately.

If the generator is to be connected to a building’s

AC power source via an automatic transfer switch (isolation), place the switch in the AUTO position. In this position, should an outage occur, the automatic transfer switch (ATS) will start the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

6. Diagnostic Switch – When activated, fault errors in the engine or the engine control system will be displayed on the engine warning module (LED's).

B. High Coolant Temperature — Indicates the engine

temperature has exceeded 212° F (100° C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault and the engine will be shut down.

C. Overcrank Shutdown — Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a major fault.

D. Overspeed Shutdown — Indicates the engine is

running at an unsafe speed. This is considered a major fault.

E. Engine Running — Indicates that engine is running

at a safe operating speed.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 19

Page 20

GENERATOR CONTROL PANEL

Intergrated Gauge Control

ECU

Low Oil Pressure

High temp.

Over Crank

Over Speed

Engine Started

U-V

INCREASE

V-W

OFF

DECREASE

W-U

Figure 5. Generator Control Panel

The deﬁnitions below describe the controls and functions of the Generator Control Panel (Figure 5).

1. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz.

2. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. AC Voltmeter — Indicates the output voltage present

at the U,V, and W output terminal lugs.

4. Engine Speed Switch – This switch controls the speed

of the engine (low/high).

5. 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.

6. Voltage Regulator Control — Allows ±15% manual

adjustment of the generator’s output voltage.

7. Emergency Stop Button (Option) — Push this button

inward to stop the engine in the event of an emergency. DO NOT use this button as a means of stopping the engine

8. Main Circuit Breaker—This three-pole, 110A main

breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.

NOTICE

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W output terminal lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 110 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 20 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 21

OUTPUT TERMINAL PANEL FAMILIARIZATION

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

HARD WIRE

HOOKUP PANEL

BLACK RED BLUE WHITE GREEN

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

NEUTRAL

TERMINAL

GROUND

TERMINAL

CIRCUIT BREAKERS FOR CS-6369 TWIST LOCK RECEPTACLES

WHISPERWATT

ACCESS DOOR

LIFT TO OPEN

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 6) shown below is located on the right-hand side (right from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds.

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel” (Figure 6) is provided with the following:

 Two 120/240V output receptacles (CS6369) @ 50 amp

 Two Auxiliary Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two Duplex Circuit Breakers @ 20 amps

 Five Output Terminal Lugs ( U, V, W, O, Ground)

120 VAC, 20 AMP

GFCI RECEPTACLES

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

AUX. POWER RECEPTACLES

240/120V, 50 AMPS

CS-6369

TWIST-LOCK

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 21

Figure 6. Output Terminal Panel

Page 22

OUTPUT TERMINAL PANEL FAMILIARIZATION

TERMINAL

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 selector switch 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 7) 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 both auxiliary receptacles is dependent on the load requirements of the Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 10). Un-screw the securing bolts (2) and raise the plastic face plate to gain access to the output terminal lugs.

Figure 7. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are two 240/120V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 8) provided on the output terminal panel. These receptacles can only be accessed when the voltage selector switch is placed in the single-

phase 240/120 position.

Figure 8. 240/120V Twist-Lock Auxiliary

Receptacles

After the load wires have been securely attached to the output terminal lugs, lower the plastic face plate, and reinstall the retaining bolts.

PLASTIC

COVER

SECURING

BOLTS

Figure 10. Plastic Face Plate

(Output Terminal Lugs)

HARD WIRE

HOOKUP PANEL

PAGE 22 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 23

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

NOTICE

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.

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

To protect the output terminals from overload, a 3-pole, 110A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An over current relay (Figure 12) 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.

Figure 12. Over Current Relay

Figure 11. Connecting Loads

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 23

Page 24

LOAD APPLICATION

SINGLE 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.

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. SeeTable 5 below when connecting loads.

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

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.

Table 5. Power Factor By Load

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

1.0

Common power tools 0.8

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

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.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

 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 switch.

PAGE 24 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 25

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage selector switch (Figure 13). 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.

Voltage Selector Switch

The voltage selector switch (Figure 13) is located above the output terminal panel’s Hard Wire Hook-up Panel. It has been provided for ease of voltage selection.

Figure 13. Voltage Selector Switch

Voltage Selector Switch Locking Button

To lock the voltage selector switch, press and hold the red button located at the bottom of the switch. While

holding the red button down, insert a pad lock into the hole next to the button to retain it in the inward locked position. When the lock is removed, the red button is spring loaded and will return to its normal outward unlocked position.

CAUTION

NEVER change the position of the voltage selector switch while the engine is running. ALWAYS place

circuit breaker in the OFF position before selecting voltage.

Table 7. Voltages Available

UVWO Output Terminal Lugs

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

1Ø Line-Neutral/

Line-Line

Voltage Selector Switch

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

Voltage Selector Switch Single-Phase 240/120V Position

120V

Line-Neutral

N/A N/A

Voltage Selector Switch

3-Phase 480/270V Position

240V

Line-Line

N/A N/A

Generator Amperage

Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed..

Table 8. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt

1Ø 240 Volt

80 amps (4 wire)

108A x 2 (Zigzag)

40 amps (4 wire)

108A (Zigzag)

3Ø 240 Volt 86 amps

3Ø 480 Volt 43 amps

GFCI Receptacle Load Capability

The load capability of the GFCI receptacles is directly related to the voltage being supplied at either the output terminals or the 2 twist lock auxiliary receptacles.

Table 9 and Table 10 show what amount of current is available at the GFCI receptacles when the output terminals and twist lock receptacles are in use. Be careful that your load does not to exceed the available current capability at the receptacles.

Table 9. 1Ø GFCI Receptacle Load Capacity

KW in Use

Twist Lock (C6369)

1Ø 240/120V

Table 10. 3Ø Generator Maximum Amps

KVA in Use

(UVWO Terminals)

3Ø 240/480V

26.0 0

24.8 5 amps/receptacle

23.6 10 amps/receptacle

22.4 15 amps/receptacle

21.2 20 amps/receptacle

31.8

27.7

23.5

19.4

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

Available Load

Current (Amps)

GFCI Duplex

5-20R 120V

0 amps/receptacle

5 amps/receptacle

10 amps/receptacle

15 amps/receptacle

20 amps/receptacle

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 25

Page 26

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.

Before taking a reading from either gauge, set the Voltage Selector Switch (Figure 14) to the position which produces the required voltage (For example, for 3Ø 240V, choose the center 3Ø 240/139V position on the voltage selector switch).

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 17) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 18). This process can be repeated for terminals V and W.

Figure 17. AC Ammeter

Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 18. AC Ammeter

(Amp Reading on U Lug)

Figure 14. Voltage Selector Switch

240/139V 3

Ø Position

NOTICE

For 3Ø 208V/1Ø,120V, place the Voltage Selector Switch in the 3 Phase 240/139 position.

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 15) 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 16)

120

Figure 15. AC Voltmeter

Change-Over Switch

Figure 16. AC Voltmeter

Gauge

PAGE 26 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 27

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 position of the Voltage Selector Switch and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage selector switch determines the range of the output voltage. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240/139 UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 19..

3. Turn the voltage regulator knob (Figure 21) 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 21. Voltage Regulator Knob

3Ø-208V/1Ø-120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 240/139 position as shown in Figure 22.

Figure 19. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 20.

Figure 20. UVWO Terminal Lugs

3Ø-240/139V Connections

Figure 22. Voltage Selector Switch

3Ø-240/139V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 23. UVWO Terminal Lugs

3Ø-208/1Ø-120V Connections Connections

NOTICE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V..

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 27

Page 28

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480/277V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 3Ø 480/277 position as shown in Figure 24.

Figure 24. Voltage Selector Switch

3Ø-480/277V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

1Ø-240/120V UVWO Terminal Output Voltages

1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 26.

Figure 26. Voltage Selector Switch

1Ø-240/120V Position

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

Figure 25. UVWO Terminal Lugs

3Ø-440/254V Connections

PAGE 28 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Figure 27. UVWO Terminal Lugs

1Ø-200/100V Connections

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a ﬁre.

Page 29

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 110 amp, main circuit breaker is provided to protect the U,V, and W output terminals from overload. In addition two single- pole, 20 amp duplex circuit breakers are provided to protect the GFCI receptacles from overload. Two 50 amp circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

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 28) on the dipstick. See Table 11 for proper selection of engine oil.

Figure 28. 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 KUBOTA Engine Owner’s Manual. Oil should be warm before draining.

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 generator enclosure frame and may also be equipped with an environmental fuel tank (Figure 29). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

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.

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

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

Table 11. Recommended Motor Oil

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 29

INTERNAL

FUEL TANK

Figure 29. Internal Fuel Tank System

FUEL

CAP

Page 30

INSPECTION/SETUP

Unlevel Ground

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 30).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

150

Level Ground

DO NOT fill on unlevel ground

Level Ground

2. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and ﬁll tank as shown in Figure 31.

DIESEL

FUEL

Figure 31. 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 32).

Figure 30. Only Fill on Level Ground

NOTICE

ONLY use low sulfur or ultra low sulfur diesel fuel when refueling.

Figure 32. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 33).

Figure 33. Fuel Expansion

PAGE 30 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 31

INSPECTION/SETUP

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

KUBOTA recommends antifreeze/summer coolant for use in

their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the

KUBOTA Engine Owner’s Manual for further details.

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 12 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 it in accordance with the KUBOTA 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

KUBOTA Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 34) when depressed with the thumb as shown below.

Table 12. Coolant Capacity

Engine and Radiator 4.75 gal (18 liters)

Reserve Tank N/A

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

Table 13. Anti-Freeze Operating Temperatures

Vol %

Anti-

Freeze

50 -37 -34 108 226

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Freezing Point Boiling Point

°C °F °C °F

Figure 34. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

0.4~0.6 IN.

(10~15MM)

DEFLECTION

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 31

Page 32

NEGATIVE

INSPECTION/SETUP

BATTERY

This unit is of negative ground DO NOT connect in reverse. Always maintain battery ﬂuid level between the speciﬁed marks. Battery life will be shortened, if the ﬂuid level are not properly maintained. Add only distilled water when replenishment is necessary.

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 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

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position. ALWAYS make sure that the MPEC Control Switch is in the OFF/RESET position when connecting the battery.

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.

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.

ALWAYS be sure the battery cables (Figure 35) 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.

POSITIVE

Figure 35. Battery Connections

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.

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

PAGE 32 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 33

GENERATOR START-UP PROCEDURE (MANUAL)

MAIN

DUPLEX

CS-6369

)

AUT

MANUAL

OFF/RESET

PRE-HEA

BEFORE STARTING

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, duplex or auxiliary circuit breakers in the ON (closed) position.

1. Place the Main, Aux. and Duplex circuit breakers (Figure 36) in the OFF position prior to starting the engine.

CIRCUIT

BREAKER

OFF

AUX. CIRCUIT

BREAKERS

OFF

CIRCUIT

BREAKERS

OFF

STARTING (MANUAL)

1. Place the voltage selector switch in the desired voltage position (Figure 38).

Figure 38. Voltage Selector Switch

2. Place the engine speed switch (Figure 39) in the LOW (down) position

LOW (DOWN

Figure 39. Engine Speed Switch (Low)

3. Place the Auto-Off/Reset Manual Switch in the MANUAL position to start the engine (Figure 40).

Figure 36. Main, Aux. and Duplex

Circuit Breakers (OFF)

2. Connect the load to the receptacles or the output terminal lugs as shown in Figure 11. These load

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

3. Tighten terminal nuts securely to prevent load wires from slipping out.

4. Close all engine enclosure doors (Figure 37).

INCORRECTCORRECT

Figure 37. Engine Enclosure Doors

Figure 40. Auto-Off/Reset Manual;Switch

(Manual Position)

4. Depending on the temperature of the coolant (cold weather conditions), the pre-heat LED (Figure 41) will light (ON) and remain on until the pre-heating cycle has been completed. After completion of the pre-heating cycle, the LED will go OFF and the engine will start.

LED

Figure 41. Pre-Heat LED

Engine Warning Unit

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 33

Page 34

GENERATOR START-UP PROCEDURE (MANUAL)

HIGH (UP)

NOTICE

In cold weather conditions warm up the engine 5-7 minutes before placing into operation.

5. In warm weather conditions let the engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem.

6. Verify that the engine started status LED on the ECU controller is on (Figure 42).

Intergrated Gauge Control

ECU

Low Oil Pressre

High temp.

Over Crank

Over Speed

Engine Started

Figure 42. ECU Controller (Engine Started LED)

8. The generator’s frequency meter (Figure 44) should be displaying the 60 cycle output frequency in HERTZ.

60 Hz

Figure 44. Frequency Meter

9. The generator’s AC-voltmeter (Figure 45) will display the generator’s output in VOLTS..

120

Figure 45. Voltmeter Meter

10. If the voltage is not within the speciﬁed tolerance use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

NOTICE

If the engine fails to start after 3 attempts, the overcrank LED on the ECU controller will turn on and the Auto-Off/Reset Switch must be placed in the Off/Reset position before the engine can be restarted.

7. If the engine is running smoothly, place the engine

speed switch (Figure 43) in the HIGH (up) position).

Figure 43. Engine Speed Switch (High)

Figure 46. Voltage Adjust Control Knob

11. The ammeter (Figure 47) 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 47. Ammeter (No Load)

PAGE 34 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 35

MAIN

DUPLEX

CS-6369

GENERATOR START-UP PROCEDURE (MANUAL)

12. Place the Main, Aux. and Duplex circuit breakers in the ON position (Figure 48).

CIRCUIT

BREAKER

AUX. CIRCUIT

BREAKERS

CIRCUIT

Figure 48. Main, Aux. and Duplex

Circuit Breakers (ON)

13. Observe the generator’s ammeter (Figure 49) 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.

Figure 49. Ammeter (Load)

14. The generator will run until manually stopped or an abnormal condition occurs.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 35

Page 36

GENERATOR START-UP PROCEDURE (AUTO)

MANUAL

OFF/RESET

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 switch.

NOTICE

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator’s internal battery charger. This will ensure that the engine will not fail due to a dead battery.

NOTICE

When the Auto Off/Reset Manual switch is placed 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.

NOTICE

The engine speed switch must be set to the “High” position when running in the auto-start mode. Failing to set the switch in the proper position can result in damage to your generator when it turns on.

STARTING (AUTO MODE)

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 50) in the AUTO position.

AUTO

Figure 50. Auto Off/Reset Manual Switch (AUTO)

In this position (AUTO), should an outage occur, the automatic transfer switch (ATS) will start the generator automatically via the generator's auto-start contacts connected to the ATS's start contacts.

Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS

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.

3. Continue operating the generator as outlined in the Manual Start-up procedure (start at step 8).

PAGE 36 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 37

DUPLEX

CS-6369

LOW (DOWN)

AUT

GENERATOR SHUT-DOWN PROCEDURES

NORMAL SHUTDOWN PROCEDURE

NOTICE

NEVER stop the engine suddenly except in an emergency.

To shutdown the generator, use the following procedure:

1. Place the Main, Aux. and Duplex circuit breakers (Figure 51) in the OFF position.

MAIN

CIRCUIT

BREAKER

OFF

AUX. CIRCUIT

BREAKERS

OFF

Figure 51. Main, Aux. and Duplex

Circuit Breakers (OFF)

2. Place the engine speed control switch (Figure 52) in the Start/Idle position (down).

CIRCUIT

BREAKERS

OFF

EMERGENCY SHUTDOWN PROCEDURE

1. If equipped (option), push the Emergency Stop

Pushbutton Switch (Figure 54).

Figure 54. Emergency Stop Button

2. If unit is not equipped with an emergency stop switch,

place the Auto Off/Reset Manual Switch (Figure 50) in the Off/Reset position.

AUTOMATIC SHUT-DOWN SYSTEM

This unit is equipped with safety devices to automatically stop the engine in the event of low oil pressure, approximately

14.2 psi (96.5 kPa), or high water temperature, approximately 212° F (100° C). The LED alarm indicators on the Engine Control Unit (ECU) illuminate to signify the reason for the shutdown.

NOTICE

Figure 52. Engine Speed Switch

Start/Idle Position

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the Auto-Off/Reset Manual Switch in the OFF/Reset position () to start the engine.

OFF/RESET

Figure 53. Auto-Off/Reset

(Off/Reset Position)

5. Remove all loads from the generator.

MANUAL

Manual;Switch

6. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

Before inspecting, place all circuit breakers in the OFF position and allow sufﬁcient time for adequate cooling. When ready to restart, complete all steps in the Generator Startup Procedure section of this manual.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 37

Page 38

MAINTENANCE

Engine

Generator

Table 14. 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 X

Change Engine Oil and Oil Filter *

Clean Unit, Inside and Outside 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 Thermostat 6000 hrs.

Check and Adjust Engine Valve Clearance X

Test Glow Plugs X

Replace Diesel Oxidation Catalyst (DOC) *

Flush and Reﬁll Cooling System 2 yrs. or 2000 hrs.

Clean Inside of Fuel Tank 1000 hrs.

Check Crankcase Ventilation Filter X .

Replace Air Cleaner Elements *

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X s

10 Hrs DAILY

250 Hrs

500 Hrs

or Every

12 Months

3000 Hrs or Every

36 Months

OTHER

4500 hrs.

As Required

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.

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 DOC Cleaning.

Replace primary air ﬁlter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

PAGE 38 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 39

MAINTENANCE

LATCH

COVER

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

AIR CLEANER

NOTICE

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 exist.

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.

NOTICE

Operating the engine with loose or damaged air cleaner components could allow unﬁltered air into the engine causing premature wear and failure.

6. To clean the primary element (paper air ﬁlter) as referenced in (Figure 55), tap the filter element several times on a hard surface to remove dirt, or blow compressed air (not to exceed 30 psi (207 kPa, 2.1 kgf/cm2) through the ﬁlter element from the inside out.

PRIMARY

AIR FILTER

ELEMENT

SECONDARY

AIR FILTER

ACUATOR

VALV E

BLOW COMPRESSED

AIR FROM THE

INSIDE OUT

ELEMENT

BODY

This Kubota diesel engine is equipped with a replaceable, high-density paper air cleaner element. This air cleaner is also equipped with an inner element (secondary) that is used as a backup ﬁlter should the primary element becomes damaged.

CAUTION

Wear protective equipment such as approved safety glasses or face shields and dust masks or respirators when cleaning air ﬁlters with compressed air.

Primary and Secondary Air Cleaner Elements

1. Release the latches (Figure 55) that secures the cover to the air cleaner body.

2. Remove the air cleaner cover and set aside.

3. Remove both the primary and secondary air cleaner elements.

4. Check the air cleaner daily or before starting the engine

Figure 55. Air Cleaner

7. Clean the secondary element (paper air ﬁlter) as referenced in step 6.

8. Replace both elements if they are damaged or excessively dirty.

9. Clean the inside of the air cleaner body.

10. Reinstall the primary and secondary air ﬁlter elements back into air cleaner body.

11. Reinstall the air cleaner cover, and secure with latches.

5. Check for and correct heavy buildup of dirt and debris along with loose or damaged components.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 39

Page 40

MAINTENANCE

ENGINE FUEL FILTER REPLACEMENT

1. Clean the area around the lubricating fuel ﬁlter head.

2. Using an oil ﬁlter wrench (Figure 56), remove fuel ﬁlter.

FUEL FILTER

HEAD

OIL

ENGINE

FUEL FILTER

CARTRIDGE

COAT SEAL

WITH THIN

LAYER OF OIL

2. Loosen the screw at the top of the ﬁlter head and also loosen the drain cock located at the bottom of the ﬁlter.

3. Let the residue or foreign substances inside the cup ﬂow into a suitable container.

4. Tighten screw and place fuel valve lever in the OPEN position.

SCREW

CLOSED

INDICATOR

MARK

DRAIN COCK

Figure 57. Fuel Filter/Water Separator

FILTER HEAD

FUEL VALVE

LEVER

CUP

FLOAT

Figure 56. Fuel Filter Removal

3. Coat the rubber seal (gasket) surface of the fuel ﬁlter with clean 15W-40 engine oil.

4. Install new oil ﬁlter ﬁrst by hand until it makes contacts with the ﬁlter head surface. Tighten it another 3/4 turn using the ﬁlter wrench.

FUEL FILTER/WATER SEPARATOR

Inspect the fuel ﬁlter water separator daily. If the fuel ﬁlter/ water separator (Figure 57) has collected a signiﬁcant amount of water and sediment at the bottom of the cup (indicator mark), it should be drained off.

Draining Of Fuel Water Separator

NOTICE

As water is collected, the red ﬂoat goes up. When the ﬂoat has reached the indicator mark (Figure 57), immediately drain the fuel water separator.

Cleaning Fuel Water Separator

NOTICE

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, air-bleed the fuel system in accordance with the KUBOTA Engine Service Manual.

To restart engine after running out of fuel, place the Auto-Off/Reset Manual Switch in the MANUAL position. Try again, if needed.

1. Place the fuel valve lever in the CLOSED position.

2. Remove cup from ﬁlter head assembly.

3. Clean inside of cup with a light oil.

4. Clean the area around the fuel ﬁlter water separator head.

5. Reattach cup to ﬁlter head assembly.

6. Place the fuel valve lever in the OPEN position.

1. Place the Open/Close fuel valve lever (Figure 57) in

the CLOSED position.

PAGE 40 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

7. Air-bleed fuel system before starting engine.

Page 41

FUEL

CRACKS

MISSING RUBBER

H (UPPER LIMIT)

(LOWER LIMIT)

MAINTENANCE

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

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 58) wash out any deposits or debris that have accumulated inside the fuel tank.

V-BELT (DAILY)

Visually examine the V-belt (Figure 59) and determine if it is full of tiny cracks, frayed, has pieces of rubber missing, is peeling, or is otherwise damaged.

Also, examine the belt and determine if it is oil soaked or "glazed " (hard shiny appearance on the sides of the belt). Either of these two conditions can cause the belt to run hot, which can weaken it and increase the danger of it breaking.

If the V-belt exhibits any of the above wear conditions, replace the V-belt immediately.

OIL SOAKED

GLAZED

CORD FAILURE

WORN BACK

COVER

TANK

Figure 58. Fuel Tank Cleaning

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

BROKEN

SIDEWALL

WEAR

Figure 59. V-Belt Inspection

ENGINE OIL (CHECK DAILY)

1. When checking or adding oil, place the machine so

the engine is level.

2. Pull the engine oil dipstick from its holder.

3. Determine if engine oil is low. Oil level should be

between the upper land lower limit (Figure 60) on the dipstick.

DO NOT

OVERFILL

Loosen the drain plug at the lower top of the fuel ﬁlter. Drain the fuel in the fuel body together with the mixed

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 41

Figure 60. Dipstick Engine Oil Level

Page 42

104

122

SEALING

MAINTENANCE

4. If oil level is low, add correct amount of engine oil to bring oil level to a normal safe level (See Recommended Viscosity Grades, Table 15.

5. Allow enough time for any added oil to make its way to the oil pan before rechecking.

Table 15. Oil Selection Chart

OIL: SAE

5W/40

10W

10W/30

10W/40

15W/40

20W/20

-14

-22

-40

-4

-10

-20

-30

-40

032

5W/30

DRAINING ENGINE OIL

1. Run the engine until the engine coolant reaches a temperature of 140° (60°C) Turn the engine off.

2. Remove the oil dipstick from its holder.

3. Next, remove oil drain bolt and sealing washer and allow the oil to drain into a suitable container.

ENGINE OIL FILTER REPLACEMENT

1. Clean the area around the lubricating oil ﬁlter head.

2. Using an oil ﬁlter wrench (Figure 62), remove engine oil ﬁlter.

RUBBER

SEAL

OIL

COAT SEAL

OIL FILTER

WRENCH

ENGINE

OIL FILTER

CARTRIDGE

Figure 62. Engine Oil Filter Removal

3. Coat the rubber seal (gasket) surface of oil ﬁlter (Figure 62) with clean 15W-40 engine oil.

4. Install new oil ﬁlter ﬁrst by hand until it makes contacts with the ﬁlter head surface. Tighten it another 3/4 turn using the ﬁlter wrench.

WITH THIN

LAYER OF OIL

WSHER

DRAIN

BOLT

Figure 61. Draining Engine Oil

4. After engine oil has been completely drained, reinstall drain bolt with sealing washer and tighten securely.

NOTICE

For composite oil pans always install a new sealing washer.

PAGE 42 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

5. Fill engine crankcase with high quality detergent oil classiﬁed "For Service CI-4. Fill to the upper limit of dipstick. DO NOT overﬁll. Reference Table 2 for engine crankcase oil capacity

6. Run the engine for several minutes. Watch for oil leakage. Shut the engine down and allow it to sit for several minutes. Top off the oil to the upper limit on the dipstick.

Page 43

MAINTENANCE

FLUSHING OUT RADIATOR AND REPLACING COOLANT

WARNING

DO NOT remove the pressure cap from the radiator

when the engine is hot! Wait until the coolant temperature is below 120°F (50°C) before removing pressure cap.

Heated coolant spray or steam can cause severe scalding and personal injury.

1. Remove the coolant (Figure 63) bolt or OPEN the drain

valve on the radiator and allow the coolant to drain into a suitable container.

DRAIN

BOLT

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 64) 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.

Figure 63. Draining Engine Coolant

2. Check hoses for softening and kinks. Check clamps for signs of leakage.

3. Tighten water cock and replace the overﬂow tank.

4. Replace with coolant as recommended by the engine manufacturer.

5. Close radiator cap tightly.

6. 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.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 43

Figure 64. Radiator Cleaning

Page 44

MAINTENANCE

ENGINE BLOCK HEATING ELEMENT ANDINTERNAL BATTERY CHARGER 120 VAC INPUT RECEPTACLES (OPTIONAL)

This generator can be equipped as an option with a engine block heating element and an internal battery charger. They are provided with electric cords to connect

to a commercial power source.

The engine block heating element and internal battery charger both require 120 VAC in order to operate. A receptacle (Figure 65 )has been provided on the output terminal panel to allow commercial power to be applied.

These units will ONLY function when commercial power has been supplied to them. When using extension cords, refer to Table 6 for the correct size and length.

The battery charger should always be connected to a commercial power source to ensure that the battery does not get discharged.

When using the generator in hot climates there is no need to apply power to jacket water heater. However, if the generator will be used in cold climates, it is best to apply power to the jacket water heater at all times.

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.

NOTICE

To ensure adequate starting capability, always have power applied to the generator's internal battery charger.

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.

 Make sure engine coolant is at proper level.

 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.

Figure 65. Battery Charger and Jacket Water

Heater (Option)

PAGE 44 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

ENGINE BLOCK

HEATING ELEMENT

BATTERY CHARGER/

ENGINE BLOCK

HEATING ELEMENT

120 VAC INPUT

RECEPTACLE

DCAMPERES

OUTPUT TERMINAL

PANELASSEMBLY

BATTERY CHARGER

TO CHASSIS

GROUND

GREEN 16 AW

TO STARTER “B”

TERMINAL

RED 16 AWG.

Page 45

MAINTENANCE

EMISSION CONTROL

The emission control system employed with this Kubota diesel engine consist of a Diesel Oxidation Catalyst (DOC).

The DOC device (Figure 66) helps 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 the DOC 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.

EMISSION CARBON CHECK

Deposition of carbon (soot, unburned fuel) in the exhaust pipe line and mufﬂer could cause not only system derates but also could lead to ﬁres.

To reduce soot and unburned fuel, run the unit at rated power until the exhaust gas become mostly colorless every 250 hours operation time. More carbon will be generated when the unit operates at less then 30% of rated power. In this case, perform the above procedures more frequently.

NOTICE

Applying a large load suddenly to the unit when the carbon deposition is generated in the exhaust system could produce sparks and will lead to abnormal combustion. Therefore, apply load gradually and observe the exhaust gas color during the process.

NOTICE

Sparks may come out of the exhaust gas outlet during load operation. Make sure the unit’s surrounding is free from any ﬂammable material.

Figure 66. Diesel Oxidation Catalyst (DOC)

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 45

Page 46

TROUBLESHOOTING DIAGNOSTICS

NOTICE

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself.

ENGINE FAULT CODE DIAGNOSTIC PROCEDURES

1. Remove all loads from the generator and place all

circuit breakers in the OFF position.

2. Shutdown the engine and open the control panel.

3. On the control panel, place the diagnostic switch

(Figure 67) in the ON (up) position to start the diagnostic process.

DIAGNOSTIC

SWITCH

OFF

Figure 67. Diagnostic Switch (ON)

 If no fault code is detected, the pre-alarm diagnostic

LED will blink repeatedly at an interval of 2.4 seconds.

NOTICE

• When a fault has been detected, the fault code will

automatically be saved as a previous code in the ECM even after the fault has been repaired.

• The pre-alarm diagnostic LED indicates the current fault code with the previous fault code in ascending order.

• When a fault occurs while the engine is running, the pre-alarm diagnostic LED will turn on indicating only the current fault has occured. Please note that the blinking fault code pattern cannot be displayed while the engine is running.

NOTICE

For a complete understanding of error codes and troubleshooting procedures, refer to the enclosed engine instruction manual.

4. The Pre-Alarm diagnostic LED will display the following:

 The pre-alarm diagnostic LED will (Figure 68) start

ﬂashing with a pattern associated with the fault 3 times at an interval of 2.4 seconds.

ENGINE SHUTDOWN

FLASHING

Figure 68. Pre-Alarm LED (Flashing)

PRE-ALARM

 If there are more than 2 fault codes are detected, the

pre-alarm diagnostic LED will repeat the detected fault codes blinking patterns in ascending order. After all the detected fault codes are shown, it will repeat the same sequence from the begining.

5. When diagnostic verﬁcation is complete be sure to

place the diagnostic switch in the OFF position (Figure 69). The engine will not start if the diagnostic switch is left in the ON position.

DIAGNOSTIC

SWITCH

OFF

Figure 69. Diagnostic Switch (OFF)

PAGE 46 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 47

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 16 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 16. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check and replace.

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.

When the Emergency/Malfunction shutdown system has been activated, the engine will be stopped and the pre-alarm LED will indicate the malfunction by a series of ﬂashing patterns. The ﬂashing patterns and corrective action are shown below in Table 17. The ﬂashing patterns consist of combinations of one or more long ﬂashes and one or more short ﬂashes.

Table 17. Engine/Generator Troubleshooting (Pre-Alarm LED)

Type of Fault Possible Fault

Engine Overspeed 115% or more rated RPM speed? Long 1 Short 1 Check electronic governor

Low Oil Pressure

Insufﬁcient Charge No Voltage of Charging Genset? Long 1 Short 3 Check wiring and repair.

High Water Temperature

Emergency Stop Emergency Stop signal detected? Long 1 Short 5 Check and repair fault

Starter Motor Protection

Rotation Sensor Defective sensor, short circuit? Long 2 Short 1 Check wiring and repair.

Solenoid Defective solenoid, short circuit? Long 2 Short 2 Check wiring and repair.

Water Temperature Sensor

Charging Gen. Terminal Disconnection Long 2 Short 6 Check connections.

Over Voltage VCC 18 volts or greater Long 3 Short 1 Check overcurrent relay.

Oil pressure 7 psi (49 kPa) or greater?

Engine Overheat, 230° F (110° C)? Long 1 Short 4 Check cooling system.

Engine Overheat, 248° F (120° C)? Long 1 Short 6 Check cooling system.

Starter motor run for 12 seconds or more?

Disconnection Long 2 Short 4 Check connection.

Short Circuit Long 2 Short 5 Check sensor. Replace.

Pre-Alarm LED

Indication

Long 1 Short 2 Check oil level.

Long 1 Short 7 Check wiring and repair.

Solution

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 47

Page 48

GENERATOR WIRING DIAGRAM

CN1

CN3

AJ C

DKB

432

CN5

CN4

CONNECTOR ARRANGEMENT

(WIRING VIEW)

CN9

V1U1W1

U2 W2

CN11

W1 U2 W2

CN12

CN7

CN8

41 98

CN10

k l

REF. DES.

MARK AT CT

CURRENT TRANSFORMERS (CT1 ~ 3)

NO MARK

NOTE: EACH CABLE IS PASSED TWICE THROUGH

CURRENT TRANSFORMERS CT1, CT2 AND CT3.

Fg ExAr ExFg

AVR

CB1

CT 1,2,3

MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR (RHEOSTAT) CURRENT TRANSFORMER CHANGE-OVER SWITCH,AMMETER AC.AMMETER

AC.VOLTMETER FREQUENCY METER CIRCUIT BREAKER, 3P 110A CIRCUIT BREAKER, 2P 50A

CIRCUIT BREAKER, 1P 20A

RECEPTACLE, CS6369, 250 VAC@ 50 AMPS

RECEPTACLE, GFCI, 125 VAC @ 20 AMPS X 2

OVER CURRENT RELAY SELECTOR SWITCH RELAY UNIT

CB2, 3

CON1, 2

CB4, 5

CON3, 4

A ~

V ~

RY1

RELAY UNIT

RY2

SYMBOL

DESIGNATION

125: 125 mm

100: 100 mm

80: 80 mm

22: 22 mm

14: 14 mm

B L BR G GR V P

BLACK BLUE BROWN GREEN GRAY VIOLET PINK

R W Y LB LG O

RED WHITE YELLOW LIGHT BLUE LIGHT GREEN ORANGE

WIRE SIZE

CODE/WIRE COLOR

5.5: 5.5 mm

8: 8 mm

NO MARK WIRE SIZE: 1.25

PAGE 48 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 49

ENGINE WIRING DIAGRAM

１５

４

１

５

６

１

５５

１

５

３

１５１

１５２

１４９

１５

０

２

５

０

２

５１

２５２

２４９

２５５

２

５６

２

５

３

２５４

Ｓ

Ｈ

２ＳＨ１

Ｖ

Ｂ

ＧＮＤ

１１

２１１

１

B L

LB LG

WIRE COLOR BLACK BLUE BROWN GREEN GRAY VIOLET PINK

ORANGE

LIGHT GREEN

LIGHT BLUE

YELLOW

WHITE

RED

SYM.

WIRE COLOR

COLOR CODE

２５３

２５５

２５６

ＳＨ２

ＳＨ１

ＧＮＤ

ＶＢ

１５５

１５４

１５０

１５１

１５６

１５３

１５２

１４９

２５０

２５４

２５２

２５１

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 49

Page 50

BATTERY CHARGER WIRING DIAGRAM

CORD, CAROL 3/C 14 AWG., P/N EE56557.

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

TO CHASSIS

GROUND

GREEN 16 AWG.

TO STARTER “B”

TERMINAL

RED 16 AWG.

NOTES:

NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

20 AMP, 5-20R RECEPTACLE, P/N HBL5369C/HUBBLE RECEPTACLE.

PAGE 50 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17)

Page 51

ENGINE BLOCK HEATER WIRING DIAGRAM

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

ENGINE

BLOCK HEATER

BLACK 14 AWG.

LINE (L)120VAC INPUT

WHITE 14 AWG.

NEUTRAL (N)

GREEN 14 AWG.

GROUND (G)

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

TEMP.

SWITCH

120 VAC

HEATING

ELEMENT

GROUND

NOTES:

NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

20 AMP, 5-20R RECEPTACLE, P/N HBL5369C/HUBBLE RECEPTACLE.

CORD, CAROL 3/C 14 AWG., P/N EE56557.

DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (07/20/17) — PAGE 51

Page 52

OPERATION MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc

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

The information and speciﬁ cations 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 speciﬁ cations, design or the information published in this publication at any time without notice and without incurring any obligations.

DENYO CO., LTD, JAPAN

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATES

Multiquip Corporate Ofﬁce MQ Parts Department

18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

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

CANADA

Multiquip Multiquip (UK) Limited Head Ofﬁce

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: infocanda@multiquip.com

Tel. (800) 421-1244 Fax (310) 537-3927

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

800-427-1244 310-537-3700

800-421-1244 310-537-3700

UNITED KINGDOM

Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinﬁeld, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk

Fax: 800-672-7877

Fax: 310-943-2249

Tel: 0161 339 2223 Fax: 0161 339 3226

, the MQ logo and the MQ Power logo

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.

Manufactured for

MQ Power Inc.

Your Local Dealer is:

MQ Power DCA40SSKU4F2 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual