MQPower WHISPERWATT DCA-36SPX Parts Manual

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Page 1

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-36SPX

60 Hz GENERATOR

(PARTS LIST NO. B2871300404 S/N 3798495~)

Revision #0 (02/12/09)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

Page 2

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 3

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 3

Page 4

MQ POWER DCA-36SPXMQ POWER DCA-36SPX

MQ POWER DCA-36SPX

MQ POWER DCA-36SPXMQ POWER DCA-36SPX

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

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

Here's How To Get Help ....................................................3

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

Parts Ordering Procedures ...............................................5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ...........................................7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-15

Generator Decals....................................................... 16-17

Installation ................................................................. 18-19

General Information ........................................................ 20

Major Components ......................................................... 21

Generator Control Panel ................................................. 23

Engine Operating Panel ............................................. 24-25

Output Terminal Panel Familiarization ........................ 26-28

Load Application ............................................................. 29

Gauge Reading ............................................................... 30

Pre-Setup .................................................................. 31-34

Generator Start-up Procedure (Manual) ..................... 35-36

Generator Start-up Procedure (Auto Mode) .................... 37

Generator Shut-Down Procedure .................................... 38

Maintenance (Engine) ................................................ 39-41

Maintenance (Trailer) ................................................. 42-45

Trailer Wiring Diagram ..................................................... 46

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

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

Troubleshooting (Engine) ........................................... 49-50

Troubleshooting (Generator) ............................................ 51

Engine Controller Troubleshooting ................................... 52

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 56-57

Engine Operating Panel Assembly ............................ 58-59

Control Box Assembly ............................................... 60-61

Engine and Radiator Assembly ................................. 62-65

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

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

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

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

Enclosure Assembly ................................................. 74-77

Rubber Seals Assembly ............................................

Nameplate and Decals .............................................. 80-81

Terms and Condition of Sale — Parts ............................ 82

Specification and part

NOTE

number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

78-79

PAGE 4 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 5

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Effective:

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■

View Parts Diagrams

■

Order Parts

Goto www.multiquip.com and click on

Order Parts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax.

Domestic (US) Customers dial:

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in

If you have an MQ Account, to obtain a Username and Password, E-mail us at:

parts@multiquip.com.

To obtain an MQ Account, contact your

internet

Use the on

Standard orders

Fax

your order in and qualify for a 2% Discount

Standard orders

Domestic (US) Dealers Call:

and qualify for a 5% Discount

for all orders which include

International Customers

tact their local Multiquip Representatives

Note: Discounts Are Subject To Change

should con-

❒❒

❒

❒❒

❒

❒❒

❒

❒❒

❒

❒❒ ❒❒

❒

❒❒

www.mqpower.com

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 5

When ordering parts, please supply:

❒❒

❒

Dealer Account Number Dealer Name and Address Shipping Address (if different than billing address) Return Fax Number Applicable Model Number

All orders are treated as and will ship the same day if received prior

WE ACCEPT ALL MAJOR CREDIT CARDS!

❒❒

Standard Orders

Specify Preferred Method of Shipment:

✓

UPS/Fed Ex

■

Priority One

■

Ground

■ Next Day

✓ DHL ✓

Truck

Page 6

DCA-36SPX — SPECIFICATIONS

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leuFleseiD2#

PAGE 6 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 7

DCA-36SPX — DIMENSIONS (TOP, SIDE AND FRONT)

TOP VIEW

Figure 1. Dimensions

SIDE VIEW

FRONT VIEW

Denyo

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm837(.ni1.92F ).mm009,1(.ni8.47

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).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 7

D).mm077(.ni3.03

E).mm536(.ni0.52

Page 8

DCA-36SPX — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-36SPX

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

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

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

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

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

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

Page 9

DCA-36SPX — SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the engine ON/OFF

switch (MPEC) in the OFF/RESET position when the generator is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

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

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

sufficient load (less than 40% of the rated output) it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbocharges, and reduce the operating performance. In order for a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel. Wet stacking does usually cause any permanent damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

CAUTION - ENGINE LOAD (WET-STACKING)

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 9

Page 10

DCA-36SPX — RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

or even

DEATH

! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the

DCA-36SPX Whisperwatt™ AC Generator.

General Safety:

■

DO NOT operate or service this equipment before reading this entire manual.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generators.

■

The engine section of this generators requires an adequate free flow of cooling air. any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generators or engine and may cause injury to people. Remember the generator's engine gives off carbon monoxide gas.

NEVER

DEADLY

operate the generators in

Denyo

DANGEROUS

GAS FUMES

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking

■

medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

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

■

Whenever necessary, replace nameplate, operation and

■

safety decals when they become difficult read.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

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

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT

smoke

around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

bodily

harm or even death.

NEVER disconnect any

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.

"emergency or safety devices"

PAGE 10 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 11

DCA-36SPX — RULES FOR SAFE OPERATION

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generators.

■

NEVER leave the generator unattended, turn off engine when unattended.

■

Unauthorized equipment modifications will void all warranties.

■

ALWAYS ensure generator is on level ground before use.

■

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

■

NEVER run engine without air cleaner. Severe engine damage

may occur.

■

NEVER change or adjust the engine speed which has been

set at the factory prior to shipping.

Power Cord Safety

■

NEVER let power cables or cords

■

NEVER is being transfer to a load.

■

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

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper power or extension cord has been selected for the job See Table 4.

stand in water

while AC power from the generators

lay in wate

Grounding Safety

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

death!

ungrounded generator.

■

ALWAYS make sure the generators are properly grounded to a suitable earth ground (GROUND ROD). See installation in this manual.

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

High Temperatures – Always stop engine and allow the engine to cool before adding fuel, oil or performing service and maintenance

hot!

functions. Contact with cause serious burns.

Keep the machinery in proper running condition. Fix damage to the machine immediately and replace any

broken parts immediately.

ALWAYS replace any worn or damaged warning decals.

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

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. performing maintenance on the generator.

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

DO NOT use food or plastic containers to dispose of hazardous waste.

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

Turn all circuit breakers OFF before

components can

ALWAYS allow the machine a proper amount of time to

cool before servicing. ALWAYS service air cleaner frequently to prevent engine

malfunction.

ALWAYS disconnect the

NEGATIVE battery terminal

before performing service on the generator. Follow all battery safety guidelines listed in this manual

when handleing or servicing the generator.

■

NEVER use

gas piping

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 11

as an electrical ground.

Page 12

DCA-36SPX — RULES FOR SAFE OPERATION

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

■

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Battery Safety

Use the following guidelines when handling the battery:

■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses.

■

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the battery to

■■

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

■■

■

ALWAYS keep the battery charged. If the battery is not

■■

charged a buildup of combustible gas will occur.

always

wear safety

severe injury

DEATH:

■■

■

ALWAYS keep battery charging and cables in good

■■

working condition. Repair or replace all worn cables.

■■

■

ALWAYS recharge the battery in an vented air

■■

environment, to avoid risk of a dangerous concentration of combustible gases.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

■■

contact with immediately with plenty of water.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

■■

contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

clothing or skin

EYES

, rinse skin or clothing

, rinse eyes immediately with

PAGE 12 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 13

DCA-36SPX — RULES FOR SAFE OPERATION

ACCIRCUIT BREAKER

OFF

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

22A

120

20A

120V

OFF

GA-2.9R

ACCIRCUIT BREAKER

120

20A

120V

OFF

GA-2.9R

DANGERDANGER

DANGER

DANGERDANGER

During operation of this generation, there exists the possibility of

electrical shock or burn

cause

severe bodily harm

DEATH!

To avoid these hazards:

NEVER use

Electrocution HazardsElectrocution Hazards

Electrocution Hazards

Electrocution HazardsElectrocution Hazards

electrocution

, which can

or even

damaged

worn

cables when connecting

Engine exhaust gases contain

poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output receptacles, incorrect connections may cause damage to the generators and electrical shock.

NEVER grab or touch a live power cord with wet hands, the possibility exist of electrical shock, electrocution, and even

death!

DANGERDANGER

DANGER

DANGERDANGER

Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards

Lethal Exhaust Gas Hazards

Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards

DANGER

Using a generator indoors .CAN KILL YOU IN MINUTES

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

20A

120

2900

GA-2.9R

ACCIRCUIT

120V

2900

ACCIRCUIT BREAKER

NEVER use inside a home or garage, even if doors and windows are open

Avoid other generator hazards.

2900

GA-2.9R

ACCIRCUIT BREAKER

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

BREAKER

OFF

.READ MANUAL BEFORE USE

Emergencies

NEVER insert any objects into

the output receptacles during

■

ALWAYS know the location of the

nearest

operation. This is extremely dangerous. ALWAYS turn-off the generators and place all circuit breakers in the “OFF” position when contact with the output receptacles is required. There exist the possibility of

electrocution,

■

ALWAYS know the location of the nearest

first aid kit

electrical shock or burn, which can cause severe bodily harm or even death

Backfeed to a utility system can cause

electrocution

NEVER connect the generators to a

building's electrical system without a transfer switch or other approved device. All installations should be performed by

licensed electrician

a with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn causing serious injury or even death!

and or property damage.

in accordance

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

fire extinguisher

always

know the location of the

keep a phone on the job site

and

fire department

. This

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 13

Page 14

DCA-36SPX — RULES FOR SAFE OPERATION

■

If your generator is trailer mounted, please read the towing and safety requirements listed below.

Towing and Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

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

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Drain fuel from generator fuel tank before towing.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

DOT Requirements include the following:



Connect and test electric brake operation.



Secure portable power cables in cable tray with tie wraps.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

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

■

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

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

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

Trailer tires should be inflated to 50 psi cold.

PAGE 14 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

NOTE

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

Page 15

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 15

Page 16

DCA-36SPX — GENERATOR DECALS

The DCA-36SPX generator is equipped with a number of safety decals (Figures 2 and 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 16 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Figure 2. Generator Decals

Page 17

DCA-36SPX — GENERATOR DECALS

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 17

Figure 3. Generator Decals (Cont inued)

Page 18

DCA-36SPX — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 18 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 19

DCA-36SPX — 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 - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

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

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

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

a. Copper - 10 AWG (5.3 mm b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 4) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

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

) or larger.

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 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

NOTE

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

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 19

Page 20

DCA-36SPX — GENERAL INFORMATION

DCA-36SPX Whisperwatt™ Series Familiarization Generator

The MQ Power Model DCA-36SPX is a 36 kW

generator

(Figure 5) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Operating Panel

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

Open Delta Excitation System

The DCA-36SPX generator is equipped with the state of the

Open-Delta

art " 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.

■■

Tachometer

■

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Panel Light/Panel Light Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

■■

■

Pre-Heat Lamp

■■

■

Pre-Heat Button

■■

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, 150 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Selector Switch

■■

Output Terminal Panel

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

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, (for CS-6369), 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Four output terminal lugs (1Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

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 " according the demands of the required load.

Engine

The DCA-36SPX is powered by a 4 cylinder, water cooled, direct injection, engine is designed to meet every performance requirement for the generator. Reference Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Electric Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

Extension Cables

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

" excitation system. The open delta system

fixed ceiling

Isuzu Model BB-4JG1T diesel engine

" and responds

. This

PAGE 20 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 21

DCA-36SPX — MAJOR COMPONENTS

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AUTO

LOWOILPRESSURE HIGHCOOLANTTEMPERATURE OVERCRANK OVERSPEED ENGINERUNNING

MANUAL

OFF/RESET

Figure 5. Major Components

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 21

Page 22

NOTE PAGE

PAGE 22 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 23

DCA-36SPX — GENERATOR CONTROL PANEL

OFF

DECREASE

INCREASE

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-36SPX

Generator Control Panel

(Figure 6).

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,O, and V Output Terminal Lugs

4. Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

■

Single Phase Circuit Breaker

■■

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

NOTE

to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

6. Main Circuit Breaker – This three-pole, 150A main breaker is provided to protect the the

Terminal Lugs

from overload.

U,O, and V Output

In the event of a short circuit or over current condition, it will automatically trip the 90 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,O and V

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 23

Page 24

DCA-36SPX — ENGINE OPERATING PANEL

PAGE 24 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Figure 7. Engine Operating Panel

Page 25

DCA-36SPX — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-36SPX

1. Panel Light – Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control panel light.

3. Oil Pressure Gauge – During normal operation this gauge be should read between 35 to 73 psi. (241~448 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

4. Water Temperature Gauge – During normal operation this gauge should read between 180° and 221°F (82° ~105°C)

5. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8. Fuel Filter Water Level Alarm Lamp– This lamp will illuminate when an excessive amount of water has accumulated in fuel filter. Drain water in the strainer immediately if this lamp is on.

9. Auto On/Off Engine Controller (MPEC) – 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

cycle

crank the engine for 10 seconds before disengaging.

Engine Operating Panel

(Figure 7).

cranking

, The MPEC will attempt to

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s

Crank Protection

(RPM's) that is not safe, the controller will shutdown the engine by initializing the

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. MPEC Control 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.

B. Low Oil Pressure – Indicates the engine pressure has

fallen below 14 psi (97 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 221°F. (105°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

D. 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 fault.

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

Over

mode. If the engine engages at a speed

Over Speed Protection

major

fault.

mode.

fault.

major

fault.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 25

F. Engine Running – Indicates that engine is running at

a safe operating speed.

Page 26

DCA-36SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Two 120/240V output receptacles (CS-6369), 50A

■■

lugs.

■■

■

Two auxilliary circuit breakers, (for CS-6369), 50A

■■

Two 120V GFCI receptacles @ 20 amp

■

■■

Two GFCI circuit breakers @ 20 amps

■

■■

■

Four Output Terminal Lugs ( U, O, V and Ground)

SINGLE PHASE

240 -120 VAC

OUTPUT TERMINALS

BLACK

WHITE

RED

■■

GROUND

TERMINAL

GREEN

” (Figure 8) is provided with the

HARD WIRE

HOOKUP PANEL

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

120 VAC, 20 AMP

GFCI RECEPTACLES

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

NEUTRAL

TERMINAL

CIRCUIT BREAKERS FOR CS-6369 TWIST

LOCK RECEPTACLES

AUX. POWER RECEPTACLES

120/240V, 50 AMPS

TWIST-LOCK

CS-6369

ACCESS DOOR

LIFT TO OPEN

PAGE 26 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Figure 8. Output Terminal Panel

Page 27

DCA-36SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

100 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These

any

receptacles can be accessed in

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, O, and V output terminal lugs.

Pressing the being tripped. Pressing the

reset

button resets the GFCI receptacle after

Test Button

(See Figure 9) in

Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

plate cover (Figure 12). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

Figure 11. Voltage Regulator Control Knob

are protected by a plastic face

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can when the voltage selector switch is placed in the

only

be accessed

single-

phase 240/120 position.

CS-6369

TWIST-LOCK

RECEPTACLES

Figure 12. Plastic Face Plate (Output Terminal Lugs)

SINGLE-PHASE

120/240 VAC

50 AMP OUTPUT

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 27

Page 28

DCA-36SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

or the convenience receptacles (Figure 13).

Ouput

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, 150A

main

circuit breaker is provided. Make sure to

Over Current Relay

over current relay

An 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 rent relay must be pressed. The over current relay is located in the control box.

switch ALL circuit breakers to the OFF position prior to starting the engine.

CS-6369

TWIST-LOCK

RECEPTACLES

LOAD

GFCI

RECEPTACLES

(Figure 14) is connected to the main

reset button

on the over cur-

Figure 14. Over Current Relay

LOAD

AC OUTPUT

TERMINALS

GROUND

LOAD

NEUTRAL

Figure 13. Connecting Loads

PAGE 28 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 29

DCA-36SPX — LOAD APPLICATION/MAXIMUM AMPERAGE

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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.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

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

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NOTE

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

■■

When connecting a resistance load such as an

■

■■

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

■■

■

When connecting a fluorescent or mercury lamp, a

■■

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

■■

pay close attention to the required starting current capacity.

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

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

(transfer) switch

electrical system may occur without this transfer switch.

Generator Amperage

Table 7 describes the generator’s current output capability.

Motors and motor-driven equipment draw much greater current for starting than during operation.

licensed electrician

must install an

. Serious damage to the building’s

isolation

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DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 29

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Page 30

DCA-36SPX — GAUGE READING/ TERMINAL PANEL CONNECTIONS

How to Read the Output Terminal Gauges.

The gauges on the control panel are provided to help observe how much power is being supplied at the

terminals lugs

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over Switch

setting (Figure 15) to activate the (Figure 16) and read the available amperage at the terminal lug.

For example, to measure the amperage at the U terminal lug, set the U and read the AC Ammeter Gauge.

to the appropriate

AC Ammeter Gauge

AC Ammeter Change-Over Switch

Output

2. Turn the voltage regulator knob (Figure 18) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 17. Output Terminal Lugs

240 Single Phase Connections

Figure 15. AC Ammeter

Change-Over Switch

NOTE

UOV Terminal Output Voltages

240/120V output voltages can be obtained using the

Terminal Lugs

The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

1Ø 240 Output Terminal Lug Voltages

1. Connect the load wires to the shown in (Figure 17)

Figure 16. AC Ammeter

(Amp reading on U lug)

The

ammeter

show a reading when the

Terminal Lugs

to a load and in use.

gauge will only

Output

are connected

Output

Output Terminal Lugs

Figure 18. Voltage Regulator Knob (139V/240V)

1Ø 120 Output Terminal Lug Voltages

1. Connect the load wires to the shown in (Figure 19)

2. Turn the voltage regulator knob (Figure 18) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Output Terminal Lugs

Figure 19. Output Terminal Lugs

120 Single Phase Connections

PAGE 30 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 31

DCA-36SPX — SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 90 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Two 50 amp

U,O, and V

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

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 20) on the dipstick. See Table 8 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 20. Engine Oil Dipstick

This generator has an internal fuel tank located inside the

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 Isuzu Engine Owner's Manual. Oil should be warm before draining.

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 8. Recommended Motor Oil

OIL: SAE

5W30

ARCTIC OIL

10W/40

15W30

20W40

10W

10W30

122

104

-14

-4

-22

-40

-10

-20

-30

-40

10W40

032

trailer frame and may also be equipped with an optional environmental fuel tank (Figure 21). tanks with clean fresh 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.

hot

engine can cause a

#2 diesel fuel.

ENVIRONMENTAL

FUEL TANK

(OPTION)

fire

explosion

ALWAYS

fill the fuel

DO NOT fill the fuel

Figure 21. Internal Fuel Tank System

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 31

Page 32

Refueling Procedure:

DCA-36SPX — SETUP

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

3. NEVER overfill fuel tank – It is important to read the

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 22).

CAUTION - REFUELING THE GENERATOR

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

Unlevel Ground

Level Ground

DO NOT fill on unlevel ground

Unlevel Ground

Level Ground

DO NOT OVER-FILL fuel system. Leave room for fuel expansion. Fuel expands when heated (Figure 25).

NOTE

If generator is equipped with an environmental fuel tank, reference

Figures 24 and 25.

fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 24).

Figure 24. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

Figure 22. Only Fill on Level Ground

NOTE

ONLY! use

#2 diesel fuel

when

refueling.

2. Remove fuel cap (internal fuel tank) and fill fuel tank as shown Figure 23.

Figure 23. Fueling the Generator

Figure 25. Fuel Expansion

PAGE 32 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 33

DCA-36SPX — SETUP

Coolant (Antifreeze/Summer Coolant/Water)

ISUZU 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 ISUZU Engine Owner's Manual for further details.

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

WARNING - BURN HAZARDS

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of 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 9 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.

hot!

coolant exists which

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the ISUZU 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 ISUZU

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 26) when depressed with the thumb as shown below.

battery terminal disconnected.

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Operation Freezing Weather

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

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When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

Figure 26. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 33

Page 34

DCA-36SPX — 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. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 27) 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 - BATTERY SERVICING SAFETY

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the the MANUAL position. ALWAYS make sure that the

Control Switch

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.

NOTE

CAUTION - BATTERY SERVICING SAFETY

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

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

MPEC Control Switch

is in either

MPEC

is in the OFF/RESET position when

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.

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 27. Battery Connections

PAGE 34 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrision 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 ( immediately.

fuel

oil

) lines are defective replace them

Page 35

DCA-36SPX — GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 28) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

ISUZUISUZUISUZU

Manual Start-up Procedure

1. Place the position to start the engine (Figure 30).

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

3. Verify that the Engine Running status LED on the MPEC unit (Figure 31) is ON (lit) after the engine has been started.

MPEC Control Switch

Figure 30. MPEC Control Switch

(Manual Position)

in the MANUAL

Figure 28. Main, Aux. and GFCI

Circuit Breakers (OFF)

3. Connect the load to the

terminal lugs

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

4. The output terminal lugs are protected by a plastic cover. Remove this cover to gain access to the terminals. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 29).

as shown in Figure 8. These load connection

Figure 29. Engine Enclosure Doors

receptacles or

INCORRECTCORRECT

the

output

4. The generator's frequency meter (Figure 32) should be

Figure 31. Engine Running LED (ON)

displaying the 60 cycle output frequency in HERTZ.

Figure 32. Frequency Meter (Hz)

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 35

Page 36

DCA-36SPX — GENERATOR START-UP PROCEDURE (MANUAL)

6. The generator's AC-voltmeter (Figure 33) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 34) to increase or decrease the desired voltage.

9. The (Figure 37) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 180~221 °F (82~105 °C),

Green Zone

10. The

Figure 33. Voltmeter

Figure 34. Voltage Adjust Control Knob

will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

11. Place the

ON position (Figure 39).

coolant temperature gauge

Figure 37. Coolant

Temperature Gauge

tachometer gauge

main, GFCI

(Figure 38)

, and

aux

. circuit breakers in the

Figure 38. Engine

Tachometer Gauge

7. The ammeter (Figure 35) will indicate applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

8. The engine oil pressure gauge (Figure 36) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (241~448 kPa). When starting the generator.

zero amps

with no load

Figure 35. Ammeter

(No Load)

Figure 36. Oil

Pressure Gauge

Figure 39. Main, Aux. and GFCI

Circuit Breakers (ON)

12. Observe the generator's ammeter (Figure 40) 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 40. Ammeter

(Load)

PAGE 36 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

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

Page 37

DCA-36SPX — GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

building’s electrical system may occur without this transfer switch.

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.

NOTE

must install an

. Serious damage to the

CAUTION - BACKUP GENERATOR USE

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

licensed

isolation

in the event of

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 5 in the

2. Place the position

3. Continue operating the generator as outlined in the

Manual Start-up Procedure

Before Starting

MPEC Control Switch

Figure 41. MPEC Control Switch (AUTO)

(Figure 41) in the AUTO

(start at step 5).

Manual

section.

WARNING - AUTO MODE MAINTENANCE

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.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 37

Page 38

DCA-36SPX — GENERATOR SHUT-DOWN PROCEDURES

WARNING -

NEVER stop the engine suddenly except in an emergency.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 39 to the OFF position.

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

3. Place the

OFF/RESET position.

Figure 42. MPEC Control Switch (Off/Reset)

4. Verify that the are OFF (not lit).

SHUTTING DOWN THE GENERATOR

MPEC Control Switch

all

status LED on the MPEC display

(Figure 42) to the

Emergency Shutdown Procedure

1. Place the the OFF/RESET position.

2. To shut-down the engine in the event of an emergency, switch the breakers to OFF position.

MPEC Control Switch

MAIN, GFCI

and

switch (Figure 42) to

LOAD

(Figure 39) circuit

5. Remove all loads from the generator.

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

PAGE 38 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 39

DCA-36SPX — MAINTENANCE

ECNANETNIAM/NOITCEPSNI.11ELBAT

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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 11 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

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

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the

Service Daily

If the engine is operating in very 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

Fuel Addition

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

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.

indicator.

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 39

dusty

if these conditions exists.

dry grass

Page 40

DCA-36SPX — MAINTENANCE

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the

Manual

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

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 31.

Replacing Oil Filter



for details.

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter. After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

VOLVO Engine

Flushing Out Radiator and Replacing Coolant



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



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



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.



Tighten both cocks and replace the overflow tank.



Replace with coolant as recommended by the engine manufaturer.



Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Generator Storage

cool

when flushing out

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Replacing Fuel Filter



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



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



Vent any air.

For longe term storage of the generator the following is recommended:



Fill 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.

PAGE 40 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 41

DCA-36SPX — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

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

The purpose of these receptacles is to provide power via commercial power to the

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 43). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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 an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 41

Figure 43. Battery Charger &

Jacket Water Heater Power Connections

Page 42

DCA-36SPX — TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-36SPX

Whisperwatt

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

™

Generator.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 16 and Figure 59 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

15. Electrical - Electrical connectors (looms) are provided

16. Application - Indicates which units can be employed

with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

on a particular trailer.

PAGE 42 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 43

DCA-36SPX — TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 44) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 44 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot

at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

Figure 44. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

5. Adjust the brake shoes outward until the pressure of the

lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction

until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

7. Replace the adjusting hole cover and lower the trailer to

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

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

sure that it is functioning correctly. Never use an undersize actuator.

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DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 43

Page 44

DCA-36SPX — TRAILER MAINTENANCE

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Suspension

leaf suspension

The (Figure 45) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 14.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

springs and associated components

Figure 45. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

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

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

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PAGE 44 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 45

DCA-36SPX — TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 46). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 15.

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

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DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 45

NOTE

Figure 46. Wheel Lug Nuts

Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Page 46

DCA-36SPX — TRAILER WIRING DIAGRAM

Figure 47. Trailer/Towing Vehicle Wiring Diagram

PAGE 46 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 47

DCA-36SPX — GENERATOR WIRING DIAGRAM

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 47

Figure 48. Generator Wiring Diagram

Page 48

DCA-36SPX — ENGINE WIRING DIAGRAM

PAGE 48 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Figure 49. Engine Wiring Diagram

Page 49

DCA-36SPX — TROUBLESHOOTING (ENGINE)

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 engine. If the problem cannot be remedied, consult our company's business office or service plant.

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dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 49

?detcennocsidgniriW .gniriwtcennoC

Page 50

DCA-36SPX — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

noitcejniesooloteudkaelleuF

?tungniniaterepip

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

.htoomstonsinoituloverenignE

?erusserp

?deggolc

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?kcuts

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?desuleufedargwoL .leufdeificepsehtesU

.tunnethgiT

.tsujdA

.ecalperroriapeR

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

PAGE 50 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

Page 51

DCA-36SPX — TROUBLESHOOTING (GENERATOR)

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

GNITOOHSELBUORTROTARENEG.71ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 51

Page 52

DCA-36SPX — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve )dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidneseca

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

lpeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

nosithgildeepsrevO

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

PAGE 52 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipci

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenign

sujdA

Page 53

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 53

Page 54

DCA-36SPX — EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. .... 1 ....

3 12348 HOSE .................... A/R .. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

, #, +, %, or >) in the number column belong to the same

(

assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTE

without notice

WASHER, 1/4 IN. ...........

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

QTY. Column

Numbers Used - Item quantity can be indicated by a number,

a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts

that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold

separately. Other entries will be clarified in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit

symbol will be included when this item is purchased. Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

range where a particular part is used. Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

PART NO. Column

Numbers Used - Part numbers can be indicated by a number,

a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part

that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

PAGE 54 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

- Indicates that the part can be

- Indicates that an item cannot be

Page 55

DCA-36SPX — SUGGESTED SPARE PARTS

DCA-36SPX WHISPER WATTGENRATOR

W/ISUZU BB-4JG1T DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

1 ......... M1310501003 .... HOSE, RADIATOR UPPER

1 ......... M1310501103 .... HOSE, RADIATOR LOWER

1 ......... 0602011053 ....... RADIATOR CAP

1 ......... 0605505070 .......FUEL CAP

1 ......... 0602122272 .......UNIT, OIL PRESSURE

1 ......... 0602123260 ....... UNIT, WATER TEMPERATURE

6 ......... 8953692993 .......FILTER, FUEL CARTRIDGE

6 ......... 8970497081 .......FILTER, OIL CARTRIDGE

3 ......... 0602046366 .......FILTER, AIR (ELEMENT)

1 ......... 0601870440 ....... CIRCUIT BREAKER, 1P, 120V @ 20A

1 ......... 0601870441 ....... CIRCUIT BREAKER, 2P, 250V @ 50A

1 ......... LY2DDC12V ....... RELAY

1 ......... 8941618410 ....... FAN BELT

1 ......... 0601820626 ....... AUTOMATIC VOLTAGE REGULATOR

1 ......... 1601840073 ....... RHEOSTAT

1 ......... 0601840121 .......KNOB, RHEOSTAT

2 ......... 0601802149 .......FUSE, 10A

NOTE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 55

Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.

Page 56

GENERATOR ASSY.

DCA-36SPX — GENERATOR ASSY.

PAGE 56 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 57

DCA-36SPX — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B2110100702 ROTOR ASSY. 1 1-1 FIELD ASSY. 1 1-2 8051070003 FAN 1 1-3 0012110035 HEX HEAD BOLT 8 1-4 0042510000 WASHER, LOCK 8 1-5 8041611004 COUPLING DISK 4

1-6 8041015003 BALANCING PLATE ................................ 1 ........... PURCHASE 1-16 AS A SET

1-7 0010310025 HEX HEAD BOLT 6 1-8 0042510000 WASHER, LOCK 6

1-9 8001026013 RECTIFIER SET PLATE ......................... 1 ........... PURCHASE 1-16 AS A SET

1-10 0601821349 RECTIFIER 2 1-11 0601822601 SURGE ABSORBER 1 1-12 8001020004 INSULATOR WASHER 1 1-13 8001020504 INSULATOR WASHER 1 1-14 0010108020 HEX HEAD BOLT 4 1-15 0040008000 WASHER, LOCK 4 1-16 0601000209 BALANCING WEIGHT KIT 1 1-17 0071906310 BEARING 1 2 B3164400203 COUPLING RING 1 3 0012108030 HEX HEAD BOLT 6 4 8081340603 STATOR ASSY 1 4-1 0845041904 GROMMET 1 4-2 0845031404 GROMMET 1 5 B3164600003 COUPLING ADAPTER 1 6 0012110030 HEX HEAD BOLT 8 7 8041358203 END BRACKET 1 8 8041350013 EXCITER FIELD ASSY 1 9 0010308065 HEX HEAD BOLT 4 10 0042608000 WASHER, LOCK 4 11 0041208000 WASHER, FLAT 4 12 0017108030 HEX HEAD BOLT 6 13 8041310024 BEARING COVER 1 14 8041312014 BEARING GASKET 1 15 0017106012 HEX HEAD BOLT 4 16 8041331014 END BRACKTET COVER 1 17 0017106012 HEX HEAD BOLT 4 18 8001333003 END BRACKET COVER 1 19 0340406040 HEX HEAD BOLT 2 20 0041206000 WASHER, FLAT 2 21 0012110030 HEX HEAD BOLT 6 22 B051332014 FAN COVER 1 23 0600815000 NUT 1 24 0605000055 RUBBER SUSPENSION 2 25 0030012000 HEX HEAD NUT 2 25A 0040012000 WASHER, LOCK 2 25B 0041212000 WASHER, FLAT 2 26 0041510000 WASHER, LOCK 14 27 0042508000 WASHER. LOCK 5

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 57

Page 58

ENGINE OPERATING PANEL ASSY.

DCA-36SPX— ENGINE OPERATING PANEL ASSY.

PAGE 58 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 59

DCA-36SPX— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602202545 CONTROLLER, ECU-9988N 1 2 0601831340 SWITCH 1 3 0602120095 TACHOMETER 1 4 0602122093 OIL PRESSURE GAUGE 1 5 0602123090 WATER TEMPERATUR GAUGE 1 6 0602121080 CHARGING AMMETER 1 7 0602125090 FUEL GAUGE 1 8 0602103092 ALARM LAMP 1 8A 0601810245 BULB, DC18V 1

9 9826800370 PANEL LIGHT .................................................... 1 ........... REPLACES P/N 0601810141

10 0601831330 PANEL LIGHT SWITCH 1 11 0027104040 MACHINE SCREW 2 11A 0207004000 SELF-LOCKING NUT 2

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 59

Page 60

CONTROL BOX ASSY. (S/N 7800001~7800129)

DCA-36SPX— CONTROL BOX ASSY.

PAGE 60 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 61

DCA-36SPX— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B2214001202 CONTROL BOX 1 2 0601870434 CIRCUIT BREAKER, 3P 150A 1 2-1 0601870490 CIRCUIT BREAKER COVER 2 3 0021004040 MACHINE SCREW 4 4 M1213500303 CONTROL BOX COVER 1 5 0016906016 HEX HEAD BOLT 4 6 0601810626 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105016 MACHINE SCREW 4 8 0601801124 CURRENT TRANSFORMER, 200/5A 2 9 0027106020 MACHINE SCREW 4

10 LY2DDC12V RELAY ............................................................... 1 ........... REPLACES 0601827656

11 PYCA1 CLIP .................................................................. 2 ........... REPLACES 0601824400

12 PTF08A SOCKET ........................................................... 1 ........... REPLACES 0601823109

13 0027104020 MACHINE SCREW 2 14 M1223000503 CONTROL PANEL 1 15 0601807641 FREQUENCY METER, 45~65 HZ 240V 1 16 0601806845 AC AMMETER, 0~200A 5A 1 17 0601801040 AMMETER CHANGE OVER SWITCH 1 18 0601800271 AC VOLTMETER, 0~300V 1 19 0601840073 VOLTAGE REGULATOR, 2W 1K 1 20 0601840121 KNOB 1 21 M1223100004 STOPPER 1 22 0027105010 MACHINE SCREW 2 23 0027105010 MACHINE SCREW 4 24 0845056404 SET SCREW 1 25 0080200007 SNAP RING 1 26 0041208000 WASHER, FLAT 1

27 8972465100 PREHEAT CONTROLLER ................................. 1 ........... REPLACES P/N 0602202506

28 0016906020 HEX HEAD BOLT 1

29 1825530401 SAFETY RELAY ............................................... 1 ........... REPLACES P/N 0602200304

30 5825500290 RELAY ............................................................... 1 ........... REPLACES P/N 0602201400

31 0016906016 HEX HEAD BOLT 3 32 0016906016 HEX HEAD BOLT 8 33 0226900430 EDGING 1 34 0601802149 FUSE,10A 2

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 61

Page 62

ENGINE AND RADIATOR ASSY.

DCA-36SPX— ENGINE AND RADIATOR ASSY.

PAGE 62 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 63

DCA-36SPX— ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1923200054 ENGINE, ISUZU BB-4JG1T PD-04 1

1A 8941618410 FAN BELT .......................................................... 1 ........... REPLACES P/N 0602011432

1-1 8970497081 OIL FILTER CARTRIDGE .................................. 1 ........... REPLACES P/N 0602041214

2 0605000048 RUBBER SUSPENSION 2 3 0030010000 HEX HEAD NUT 2 4 0040010000 WASHER, LOCK 2 5 0041210000 WASHER, FLAT 2 6 M1923200064 RADIATOR 1 6-1 0602011053 RADIATOR CAP 1 6-2 M1493105204 ACOUSTIC SHEET 2 6-3 M9200100904 PLUG 1 6-4 Y0150000016 O-RING 1 7 0016908020 HEX HEAD BOLT 6 8 M1310501003 RADIATOR HOSE, UPPER 1 9 M1310501103 RADIATOR HOSE, LOWER 1 10 0605515147 HOSE BAND 4 11 M1310300903 FAN SHROUD 1 12 0016908020 HEX HEAD BOLT 4 13 M1310300504 FAN GUARD 1 14 M1310300604 FAN GUARD 1 15 0016908020 HEX HEAD BOLT 6 16 0602046275 AIR CLEANER 1 16A 0602046366 AIR CLEANER ELEMENT 1 17 0602040690 AIR CLEANER INDICATOR 1 19 0016908030 HEX HEAD BOLT 2 20 M1373100703 AIR CLEANER HOSE 1 21 M1373100603 AIR CLEANER HOSE 1 22 0605515142 HOSE BAND 1 23 0605515141 HOSE BAND 2 24 0602022560 ADAPTER 1 25 M1320300304 PACKING 1 26 0602022561 90 DEGREE ELBOW 1 27 0603306590 CONNECTOR 1 28 0603300285 ROCKNUT 1 29 0605511395 VALVE 1 30 0603306395 HOSE JOINT 1 31 0602021070 CAP 1 32 0269200500 DRAIN HOSE 1 33 7812014003 DRAIN JOINT 1 34 0802011104 PLUG 1 35 0150000018 O-RING 1 36 0016906020 HEX HEAD BOLT 2 37 0199900700 DRAIN HOSE 1 38 0605515106 HOSE BAND 2 39 0802081403 RESERVE TANK 1

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 63

Page 64

ENGINE & RADIATOR ASSY.

DCA-36SPX— ENGINE AND RADIATOR ASSY.

PAGE 64 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 65

DCA-36SPX— ENGINE AND RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

40 0802081104 RESERVE TANK CAP 1 41 0199100215 HOSE 1 42 M1317100004 RESERVE TANK BRACKET 1 43 0016908020 HEX HEAD BOLT 1 44 0199100800 HOSE 1 45 0193601200 HOSE 1 46 0605515106 HOSE BAND 2 47 0602220910 CLAMP 2 48 0016908020 HEX HEAD BOLT 2 49 0199800700 DRAIN HOSE 1 50 0269200850 BLOWBY HOSE 1 51 0605515198 HOSE BAND 2 52 RCT-2010 CLAMP 1 53 0016908020 HEX HEAD BOLT 1 54 0602120465 TACHOMETER PICK UP 1 55 0602122272 OIL PRESSURE UNIT 1 56 M9200100004 ADAPTER 1 57 0602123260 WATER PRESSURE UNIT 1

58 9095720140 PACKING........................................................... 1 ........... REPLACES P/N 0602021109

59 1819001902 ENGINE STOPPER ........................................... 1 ........... REPLACES P/N 0602210810

60 M1354200404 ENGINE STOPPER BRACKET 1 61 0027106016 MACHINE SCREW 3 62 0016908025 HEX HEAD BOLT 2

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 65

Page 66

OUTPUT TERMINAL ASSY.

DCA-36SPX— OUTPUT TERMINAL ASSY.

PAGE 66 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 67

DCA-36SPX— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B2231700303 TERMINAL PANEL 1 2 0840312904 OUTPUT TERMINAL BOLT 4 3 0801830704 TIE BOLT 4 4 0039312000 HEX HEAD NUT 8 5 0040012000 WASHER, LOCK 12 6 0041412000 WASHER, FLAT 16 7 0016908030 HEX HEAD BOLT 5 8 M1236100613 TERMINAL COVER 1 9 M1236100704 OUTPUT WINDOW 1 10 060510040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX HEAD NUT 4 11B 0041203000 WASHER, FLAT 4 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX HEAD NUT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 8085183004 CABLE OUTLET COVER 1 16 8085182004 CABLE OUTLET COVER SUPPORTER 1 17 0016906020 HEX HEAD BOLT 6 18 0601870440 CIRCUIT BREAKER, 1P@20 AMPS 2 19 0601870441 CIRCUIT BREAKER, 2P@50 AMPS 3 20 M1260700504 BREAKER FITTING COVER 1 20-1 0222100100 CUSHION RUBBER 2 21 0016906020 HEX HEAD BOLT 2 22 0601812598 RECEPTACLE, GFCI125V 20AX2 2 23 0601812565 RECEPTACLE, CS6369 250V 50A 3 24 0027104016 MACHINE SCREW 10 24A 0207004000 SELF-LOCKING NUT 10 25 M1236100803 TERMINAL COVER 1 26 0010112045 HEX HEAD BOLT 2 27 0041212000 WASHER, FLAT 2 28 0805009804 STAY RUBBER 2 29 0030012000 HEX HEAD NUT 2 30 B4234500804 COVER 1 31 0016906016 MACHINE SCREW 6 32 0601815324 TERMINAL BOARD 1 33 0027104016 MACHINE SCREW 2

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 67

Page 68

BATTERY ASSY.

DCA-36SPX— BATTERY ASSY.

PAGE 68 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 69

DCA-36SPX— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220187 BATTERY 1 2 B9310500004 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1

4 0602220920 BATTERY BOLT SET ........................................ 2 ........... INCLUDES ITEM W/ #

5 0040006000 WASHER, LOCK 2 6 M1346200004 BATTERY CABLE 1 7 M1347200104 BATTERY CABLE 1 8 0017110020 HEX HEAD BOLT 2 9 0040510000 TOOTHED WASHER 2

10 BATTERY CABLE, GROUND ............................ 1 ........... MAKE LOCALLY

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 69

Page 70

MUFFLER ASSY.

DCA-36SPX— MUFFLER ASSY.

PAGE 70 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 71

DCA-36SPX— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B3923200044 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M1333002503 EXHAUST PIPE 1

4 8943690210 GASKET ........................................................... 1 ........... REPLACES P/N 0602320101

5 B3333200104 GASKET 1 6 0039308000 HEX HEAD NUT 6 7 0016908035 HEX HEAD BOLT 4 8 M1330400304 COVER 1 9 M1333300004 BRACKET 1 10 0016906015 HEX HEAD BOLT 4 11 0602326090 U-BOLT SET 1

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 71

Page 72

FUEL TANK ASSY.

DCA-36SPX— FUEL TANK ASSY.

PAGE 72 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 73

DCA-36SPX— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1363001602 FUEL TANK 1 2 0605505070 FUEL TANK CAP 1 3 M1363200104 TANK BAND 2 4 0805003414 SUPPORTER SHEET 4 5 0016908020 HEX HEAD BOLT 2 6 0207308000 HEX NUT 2 7 0222100600 RUBBER SHEET 1 7-1 0222100085 RUBBER SHEET 2 8 1502025103 DRAIN JOINT 1 9 0802011104 DRAIN BOLT 1 10 0150000018 O RING 1 11 0016906020 HEX HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515064 HOSE BAND 2

14 8943672922 FUEL FILTER .................................................... 1 ........... REPLACES P/N 0602042202

14A 8943692993 FUEL FILTER CARTRIDGE .............................. 1 ........... REPLACES P/N 0602042700

15 0016908020 HEX HEAD BOLT 2 16 0602220911 CLAMP 2 17 0016908020 HEX HEAD BOLT 2 18 0191201400 SUCTION HOSE 1 19 0191201600 SUCTION HOSE 1 20 0191301100 RETURN HOSE 1 21 0605515108 HOSE BAND 4 22 0605515109 HOSE BAND 2

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 73

Page 74

ENCLOSURE ASSY.

DCA-36SPX— ENCLOSURE ASSY.

PAGE 74 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 75

DCA-36SPX— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1413002902 BASE 1 2 M1413400004 UNDER COVER 1 3 0016908020 HEX HEAD BOLT 2 4 M1423001902 FRONT FRAME 1 4A M1493106713 ACOUSTIC SHEET 1 5 0016908020 HEX HEAD BOLT 4 6 M1423200604 FRONT FRAME COVER 1 6A M1493100804 ACOUSTIC SHEET 1 7 0019208020 HEX HEAD BOLT 12 8 M1423201403 FRONT FRAME INNER COVER 1 9 0016908020 HEX HEAD BOLT 4 10 M1433000803 CENTER FRAME 1 11 M1433001003 CENTER FRAME 1 12 0010114030 HEX HEAD BOLT 8 12A 0040014000 WASHER, LOCK 8 12B 0041214000 WASHER, FLAT 8 13 0010114030 HEX HEAD BOLT 8 13A 0040014000 WASHER, LOCK 8 13B 0041214000 WASHER, FLAT 8 14 B2444000302 REAR FRAME 1 14A M1493300504 ACOUSTIC SHEET 1 15 0016908020 HEX HEAD BOLT 4 16 B2444300603 REAR COVER 1 17 B2444300703 REAR COVER DUCT 1 17A B2494300204 ACOUSTIC SHEET 1 18 0207006000 HEX HEAD BOLT 12 19 0019208020 HEX HEAD BOLT 9 20 M1443200803 REAR DOOR 1 21 M1443600204 WINDOW PLATE 1 22 0037906000 SELF-LOCKING NUT 8 22A 0041206000 WASHER, FLAT 8 23 B9114000002 DOOR HANDLE ASSY. 1 24 0021806016 MACHINE SCREW 4 24A 0030006000 HEX HEAD NUT 4 25 0845047104 HINGE 2 26 0845045004 WASHER 2 27 0019208025 HEX HEAD BOLT 3 27A 0027208025 MACHINE SCREW 1 28 0845031504 BLIND PLUG 2 29 M1463001802 ROOF PANEL 1 29A M1493503403 ACOUSTIC SHEET 1 30 0019208020 HEX HEAD BOLT 19 33 B2454202702 SPLASHER PANEL 1 33A M1493300204 ACOUSTIC SHEET 1

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Page 76

ENCLOSURE ASSY. (CONT.)

DCA-36SPX— ENCLOSURE ASSY. (CONT.)

PAGE 76 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 77

DCA-36SPX— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

34 0019108055 HEX HEAD BOLT 4 34A 0042308000 WASHER, LOCK 4 34B 0042408000 WASHER, FLAT 4 35 0016908020 HEX HEAD BOLT 2 36 M1453003403 SIDE DOOR 1 36A M1493406304 ACOUSTIC SHEET 1 37 M1453003503 SIDE DOOR 1 37A M1493406404 ACOUSTIC SHEET 1 38 M1453001303 SIDE DOOR 1 38A M1493400404 ACOUSTIC SHEET 1 39 M1453003603 SIDE DOOR 1 39A M1493406504 ACOUSTIC SHEET 1 40 M1453301104 DUCT 2 40A M1493405504 ACOUSTIC SHEET 2 41 B3454300804 DUCT 1 41A M1493407904 ACOUSTIC SHEET 1 42 0207006000 HEX HEAD NUT 15 43 B9114000002 DOOR HANDLE ASSY. 3 44 0021806016 MACHINE SCREW 12 44A 0030006000 HEX HEAD NUT 12 45 0845047104 HINGE 4 46 0845047204 HINGE 4 47 0845045004 WASHER 8 48 0019208000 HEX HEAD BOLT 9 48A 0027208025 MACHINE SCREW 7 49 0601850097 DOOR STOPPER 8 50 0027208025 MACHINE SCREW 8 51 M9310000004 BLIND PLUG 8 52 0600500090 EMBLEM 1 53 0021106015 MACHINE SCREW 2 54 0016908020 HEX HEAD BOLT 1 54A 0040508000 TOOTHED WASHER 1 55 0017110020 HEX HEAD BOLT 1 55A 0040510000 TOOTHED WASHER 1 56 1625165103 BONNET CAP 1 57 1625165204 CHAIN ASSY. 1 57-1 0016908020 HEX HEAD BOLT 1

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 77

Page 78

RUBBER SEALS ASSY.

DCA-36SPX— RUBBER SEALS ASSY.

PAGE 78 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 79

DCA-36SPX— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901350 RUBBER SEAL 3 2 0229200660 RUBBER SEAL 1 3 0228900610 RUBBER SEAL 1 4 0228900970 RUBBER SEAL 3 5 M1490300104 RUBBER SEAL 1 6 0228800515 RUBBER SEAL 1 7 0228900485 RUBBER SEAL 1 8 0228900910 RUBBER SEAL 1 9 0229200900 RUBBER SEAL 2 10 0229200840 RUBBER SEAL 1 11 0228800770 RUBBER SEAL 2 12 0228800470 RUBBER SEAL 1 13 0228800510 RUBBER SEAL 1 14 0228100545 RUBBER SEAL 1 15 0228100370 RUBBER SEAL 1 16 0228100165 RUBBER SEAL 1 17 0228100340 RUBBER SEAL 1 18 0228100170 RUBBER SEAL 1 19 0228100200 RUBBER SEAL 1

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 79

Page 80

NAMEPLATE AND DECALS ASSY.

DCA-36SPX— NAMEPLATE AND DECALS ASSY.

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Page 81

NAMEPLATE AND DECALS ASSY.

DCA-36SPX— NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B2551000403 DECAL : HANDLING PROCEDURES ................ 1 ........... B25100040

2 M1550001304 DECAL : CAUTION ............................................ 1 ........... M15000130

3 B2551000203 DECAL : GENERATOR CONTROL .................... 1 ........... B25200020

4 B2551000303 DECAL : ENGINE OPERATING ........................ 1 ........... B25100030

5 M1550002203 DECAL : AUXILLARY OUTPUT ......................... 1 ........... M15000220

6 A9504000004 DECAL : CAUTION ............................................ 1 ........... A90400000

7 6360620204 DECAL : OIL DRAIN PLUG ............................... 1 ........... S-1885

8 6360610304 DECAL : WATER ................................................ 1 ........... S-1880

9 6360620104 DECAL : WATER DRAIN .................................... 1 ........... S-1884

10 0800689404 DECAL : - .......................................................... 1 ........... S-2090

11 0800689504 DECAL : + ......................................................... 1 ........... S-2091

12 1320620904 DECAL : DIESEL FUEL ..................................... 1 ........... S-1756

13 6360620004 DECAL : FUEL DRAIN PLUG ............................ 1 ........... S-1883

14 B9505000505 DECAL : WARNING ........................................... 2 ........... B90400040

15 1320610603 DECAL : WATER - OIL CHECK ........................ 1 ........... S-176016

16 B9504100104 DECAL : WARNING ........................................... 1 ........... B90420000

17 B9504200004 DECAL : WARNING ........................................... 1 ........... B90420000

18 B9504000304 DECAL : CAUTION ............................................ 1 ........... B90400030

19 0840625902 DECAL : MQ ...................................................... 1 ........... S-3057

20 0840614104 DECAL : GROUND ............................................ 1 ........... S-2635

21 0840505604 DECAL : AMMETER CHANGE-OVER SW. ....... 1 ........... N-4590

23 B9531100604 DECAL : WARNING ........................................... 2 ........... B93110060

25 B9521100404 DECAL : SAFETY INSTRUCTIONS .................. 1 ........... B92110040

26 M9520100404 DECAL : DANGER HIGH VOLTAGE .................. 1 ........... M92010040

27 M9520100503 DECAL : WARNING ........................................... 1 ........... M92010050

28 C9522100003 DECAL : CAUTION ............................................ 1 ........... C92210000

29 9039209064 DECAL : START CONTACT ............................... 1 ........... S-4468

30 M1560100603 STRIPE : WHISPERWATT 1 31 M1560101904 STRIPE 2 32 M1560102003 STRIPE : MQ POWER 1 33 M1560101104 STRIPE 2 34 B2561100004 STRIPE : 36 2 35 M1560102103 STRIPE : MQ POWER 1

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 81

Page 82

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Retur n Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates

for price declines and added charges for price dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such wr itten statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 82 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)

Page 83

NOTE PAGE

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 83

Page 84

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

ON-HAND

WHEN CALLING

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551 Suite 500/600 Fax (972) 315-1847 Lewisville, TX 75057 Contact: mqpower@multiquip.com Web: www.mqpower.com

MQ Parts Department

800-427-1244 Fax: 800-672-7877 310-537-3700 Fax: 310-637-3284

Service/Tech Support/Warranty

800-835-2551 Fax: 310-638-8046

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published in this publication at any time without notice and without incurring any obligations.

Manufactured for

Multiquip Inc.

Your Local Dealer is:

DENYO CO., LTD, JAPAN

MQPower WHISPERWATT DCA-36SPX Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual