Multiquip DCA10SPX3 User Manual
OPERATION AND PARTS MANUAL
®
MODEL DCA10SPX3
60 Hz GENERATOR
(KUBOTA D1403 DIESEL ENGINE)
Revision #2 (01/17/11)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PAGE 2 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help .......................................... 3
Table Of Contents ................................................... 4
Parts Ordering Procedures ..................................... 5
Rules For Safe Operation .................................... 6-9
Towing Safety ........................................................ 10
Trailer Safety Guidelines .................................. 11-15
Trailer Wiring Diagram ........................................... 16
Operation and Safety Decals ........................... 17-18
Specifications ........................................................ 19
General Information .............................................. 20
Major Components ............................................... 21
Dimensions ...................................................... 22-23
Controls and Indicators .................................... 24-25
Output Terminals .............................................. 26-27
Installation ........................................................ 28-29
Pre-Setup ......................................................... 30-33
Load Application ................................................... 34
Start up Procedure .......................................... 35-36
Shut down Procedure ........................................... 37
Maintenance .................................................... 38-39
Generator Wiring Diagram .................................... 40
Engine Wiring Diagram ......................................... 41
Troubleshooting (Engine) ................................. 42-43
Troubleshooting (Generator) ................................ 44
Explanation Of Codes In Remarks Column .......... 46
Suggested Spare Parts ......................................... 47
DCA-10SPX3
AC Generator
Generator Assembly ........................................ 48-49
Control Panel Assembly ................................... 50-51
Output Terminal Assembly ............................... 52-53
Engine and Radiator Assembly........................ 54-55
Battery Assembly ............................................. 56-57
Muffler Assembly ............................................. 58-59
Fuel Filter Assembly ........................................ 60-61
Enclosure Assembly ......................................... 62-63
Rubber Seal Assembly..................................... 64-65
Decal Assembly ............................................... 66-67
Kubota D1403 Engine
Crankcase Assembly ....................................... 68-69
Oil Pan Assembly ............................................. 70-71
Cylinder Head Assembly .................................. 72-73
Gear Case Assembly ....................................... 74-75
Main Bearing Case Assembly .......................... 76-77
Inlet Manifold Assembly ................................... 78-79
Exhaust Manifold Assembly ............................. 80-81
Valve and Rocker Assembly ............................ 82-83
Head Cover Assembly ..................................... 84-85
Camshaft Assembly ......................................... 86-87
Piston and Camshaft Assembly ....................... 88-89
Flywheel Assembly .......................................... 90-91
Starter Assembly ............................................. 92-93
Starter Components Assembly ........................ 94-95
Injection Pump 1 Assembly .............................. 96-97
Injection Pump 1 Assembly .............................. 98-99
Fuel Camshaft Assembly ............................. 100-101
Governor Assembly ..................................... 102-103
Speed Control Plate Assembly .................... 104-105
Engine Stop Lever Assembly ....................... 106-107
Stop Solenoid Assembly .............................. 108-109
Alternator Assembly ..................................... 110-111
Alternator Components Assembly ............... 112-113
Fan Assembly ............................................... 114-115
Water Flange and Thermostat Assembly ..... 116-117
Water Pump Assembly ................................. 118-119
Radiator Assembly ....................................... 120-121
Fuel Filter Assembly .................................... 122-123
Terms and Condition of Sale-Parts ..................... 124
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
r
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
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 you
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
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
❒ Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓ DHL
■ Priority One ✓ Truck
■ Ground
■ Next Day
■ Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 5
RULES FOR SAFE OPERATION
■
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
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
GENERAL SAFETY
■
DO NOT operate or service this equipment before
reading this entire manual.
■
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.
DCA-10SPX3 portable generator:
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to
cool before servicing engine or
generator.
■
High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact
hot
with
■
The engine of this generator requires an adequate free flow
of cooling air. Never operate the generator in any enclosed or
narrow area where free flow of the air is restricted. If the air
components can cause serious burns.
flow is restricted it will cause
serious damage to the
generator or engine and may
cause injury to people. The
generator engine gives off
DEADLY carbon monoxide
gas.
■
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.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage to
the equipment and/or injury to user may result.
■
Manufacture does not assume responsibility for any accident
due to equipment modifications.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
Always check the machine for loosened threads or bolts before
starting.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
■
■
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
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
■
explosive atmosphere or near
combustible materials. An explosion or
fire could result causing severe
harm or even death.
Topping-off to filler port is dangerous, as it tends to spill fuel.
smoke around or near the
NEVER operate the generator in an
bodily
PAGE 6 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
■
NEVER touch output terminals during operation. This is
extremely dangerous.
with the output terminals is required.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
Always stop the machine when contact
RULES FOR SAFE OPERATION
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
DO NOT touch or open any of the below
mentioned components while the generator
is running. Always allow sufficient time for
the engine and generator to cool before
performing maintenance.
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Backfeed to a utility system can cause electrocution
and/or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
■
Never use damaged or worn cables when connecting power
tools or equipment to the generator. Make sure power
connecting cables are securely connected to the generator's
output terminals, insufficient tightening of the terminal
connections may cause damage to the generator and
electrical shock.
2. Coolant Drain Plug - Removing the coolant drain plug
3. Engine Oil Drain Plug - Removing the engine oil drain
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 7
RULES FOR SAFE OPERATION
■
Battery
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
■
Never over fill the battery with water above
the upper limit.
The battery has acids that can cause injury to the eyes and skin.
To avoid eye irritation, always wear safety glasses. Use well
insulated gloves when picking up the battery. Use the following
guidelines when handling the battery:
NEVER Run engine without air filter. Severe engine damage
may occur.
■
Always service air cleaner frequently to prevent carburetor
malfunction.
■
Always disconnect the battery before performing service on
the generator.
■
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
■
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.
■
DO NOT leave the generator running in the manual mode
unattended.
■
DO NOT allow unauthorized people to operate this
equipment.
■
Always read, understand, and follow procedures in Operator’s
Manual before attempting to operate equipment.
■
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
■
Refer to the
technical questions or information.
1. DO NOT drop the battery. There is the possibility of risk
the battery may explode.
2. 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.
3. Always keep the battery charged. If the battery is not
charged, a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
clothing or skin
, rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
Loading and Unloading (Crane)
■
Before lifting, make sure the generator's lifting hook is secure
and that there is no apparent damage to the generator itself
(loose screws, nuts and bolts). If any part is loose or damaged,
please take corrective action before lifting.
■
Always drain fuel prior to lifting.
■
Always make sure crane or lifting device has been properly
secured to the hook of guard frame on generator.
■
NEVER lift the machine while the engine is running.
■
Use adequate lifting cable (wire or rope) of sufficient strength.
■
When lifting the generator, always use the balanced centerpoint suspension hook and lift straight upwards.
■
NEVER allow any person or animal to stand underneath the
machine while lifting.
■
When loading the generator on a truck, be sure to use the
front and back frame bars as a means to secure the generator
during transport.
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or
hospital, and seek medical attention.
Kubota Engine Owner's Manual
for engine
PAGE 8 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
RULES FOR SAFE OPERATION
Transporting
■
Always shutdown engine before transporting.
■
Tighten fuel tank cap securely.
■
Drain fuel when transporting generator over long distances
or bad roads.
■
Always tie-down the generator during transportation by
securing the generator.
■
If generator is mounted on a trailer, make sure trailer complies
with all local and state safety transportation laws. See page
10 for basic towing procedures.
Emergencies
■
Always know the location of the nearest
and
first aid kit
Also know the phone numbers of the nearest
doctor
and
. Know the location of the nearest telephone.
fire department
.
fire extinguisher
ambulance
Maintenance Safety
■
■
■
■
■
■
,
■
NEVER lubricate components or attempt service on a
running machine.
Always allow the machine a proper amount of time to cool
before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts.
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel,
coolant and fuel filters.
DO NOT use plastic containers to dispose of hazardous
waste.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 9
DCA-10SPX3 — TOWING
Towing Safety Precautions
CAUTION :CAUTION :
CAUTION :
CAUTION :CAUTION :
Check with your county or state safety
towing regulations department before
towing your generator. Vehicle towing
codes and regulations can vary from state
to state.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
and the towing vehicle are in good operating condition and
both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■
Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).
■
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 the towing vehicle and
the 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 chain to bumper of towing
vehicle.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and are
working properly.
■
The maximum speed (unless otherwise posted) for highway
towing is 45 MPH. Recommended off-road towing is not to
exceed 10 MPH or less, depending on type of terrain.
■
Place
while parked.
■
Place
prevent
■
Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.
■
Avoid sudden stops and starts. This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
■
Avoid sharp turns to prevent rolling.
■
Remove wheel stand when transporting.
■
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
tipping
underneath wheel to prevent
underneath the trailer's bumper to
, while parked.
rolling,
Figure 1. DCA-10SPX3 and Towing Trailer
PAGE 10 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — TRAILER-SAFETY GUIDELINES
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
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 - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This 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.
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 4 and Figure 5 or 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 (see Table 3). Please not 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.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 11
DCA-10SPX3 —TRAILER-SPECIFICATIONS
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PAGE 12 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 —TRAILER-SPECIFICATIONS
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DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 13
DCA-10SPX3 — TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked,
the air
pressure in
the inner tube may cause pieces
of the rim to explode (break off)
with great force and cause serious
eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components
(Figure 2) 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
as detailed in Table 3.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
PAGE 14 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
Figure 2. Major Suspension Components
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TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
DCA-10SPX3 — TRAILER SAFETY GUIDELINES
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SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
SNUG FI T ONLY. P ARTS MUST ROTATE FREELY.
LOC K ING NUTS O R COTTER P IN S ARE PRO V IDE D TO
RETAI N NUT
-BOLT ASSEMBLY.
05-XAM03-NIM
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 3. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
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5152-0206-05021-09
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Figure 3. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 15
DCA-10SPX3 —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 16 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 —OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA10SPX3 generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding pages show these decals as they appear on the machine.
Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 17
Machine Safety Decals
DCA-10SPX3 —OPERATION AND SAFETY DECALS
PAGE 18 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — SPECIFICATIONS
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DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 19
DCA-10SPX3 — GENERAL INFORMATION
DCA-10SPX3 3 FAMILIARIZATION
Generator
The MQ Power Model DCA-10SPX3 is a 10 kW
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.
Control Panel
The control panel is provided with the following:
One GFCI 120 volt receptacle, 20 amp (single-phase)
10 kW Output Terminal (UNV)
Main Circuit Breaker 45 amps
GFCI Circuit Breaker 20 amps
AC Ammeter
AC Voltmeter
Output Voltage Adjustment
Ignition Switch
Water Temperature Gauge
Oil Pressure Gauge
Warning Indicator
Frequency Meter (Hz)
Hour Meter
Ground Terminal
generator
Open Delta Excitation System
The DCA-10SPX3 generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four Leads: A, B, C and D. During light loads, the
power to the
from the leads of B & C, when loads increase, the AVR
switches and accepts power from leads A & D. The output
of leads A & D increase proportionally with load. This has
the effect of adding the voltages of each phase to provide
better voltage response during heavy loads.
The connections of the AVR to the AC output windings are
for the sole purpose of sensing only. No power is required
from these windings.
The open-delta design provides virtually unlimited excitation
current due to its independent power supply offering
maximum motor starting capabilities. The excitation does
not have a "
demands of the required load.
Engine
The DCA-10SPX3 is powered by a 3-cylinder KUBOTA Model
D1403
performance requirement for the generator. Reference Table
5, page 19 for engine specifications.
diesel
Open-Delta
Automatic Voltage Regulator
fixed ceiling
engine. This engine is designed to meet every
" excitation system. The open delta
(AVR) is supplied
" and responds according the
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
PAGE 20 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — MAJOR COMPONENTS
Figure 4. DCA10SPX3 Generator Major Components
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 21
DCA-10SPX3 — DIMENSIONS (TOP & SIDE)
Figure 5a. Dimensions (Top & Side)
PAGE 22 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — DIMENSIONS (FRONT, REAR & BOTTOM)
Figure 5b. Dimensions (Front, Rear)
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 23
DCA-10SPX3 — CONTROL PANEL, CONTROLS AND INDICATORS
Figure 6. Control Panel
PAGE 24 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — CONTROL PANEL, CONTROLS AND INDICATORS
The definitions below describe the controls and functions
of the DCA-10SPX3 (Figure 6):
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
2. AC Ammeter – Indicates the amount of current the
load is being drawn from the generator.
3. AC Voltmeter – Indicates the single phase output
voltage present at the UNV terminals.
4. Engine Warning Display Module – This module
displays the following engine failures:
A. Overheat Lamp – This lamp goes ON
when the coolant is over 215
lamp goes ON during normal operation
of the generator, the emergency shutdown device will stop the engine
automatically.
B. Low Oil Pressure Lamp – During
normal operation of the generator this
lamp should remain OFF. After the oil
pressure rises after start-up, the lamp
will go OFF. If this lamp is ever lit (ON)
during normal operation of the generator, the emergency
shut-down device will stop the engine automatically.
C. Low Fuel Level Lamp – When this lamp
is ON, it is time to stop the engine and
add fuel. Remember to let the engine cool
before adding fuel.
o
F. If the
5. Ignition Switch - This switch turns on and off the
engine with a key.
6. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
7. Hour Meter - This meter monitors the number of hours
the generator has been running. Use this meter to
schedule regular maintenance.
8. Oil Pressure Gauge – During normal operation this
gauge be should read in the “GREEN” zone. When
starting the generator, the oil pressure mark reads
higher, but after the engine warms up the oil pressure
should return to the green zone.
9. Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
10. A.C. GCFI Receptacle - This output receptacle is used
as a power source.
11. Ground Terminal - This is used to ground the
generator.
12. UNV Terminal - Used to connect AC load for 120V
or 240V single phase.
13. Main Circuit Breaker – This three-pole,20 amp main
breaker is provided to protect the UNV voltage output
terminals from overload.
14. GCFI Receptacle Circuit Breaker - This will shut down
the output receptacle if there in an overload.
D. Low Battery Fluid Lamp – This lamp
goes ON when the battery fluid is low. If
this lamp goes ON during normal operation
of the generator, stop the engine and fill
the battery with distilled water to the
specified level.
E. Clogged Air Filter Lamp – This lamp
goes ON when the air filter is clogged. If
this lamp goes ON during normal
operation of the generator, stop the
engine and replace the air filter.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 25
DCA10SPX3 OUTPUT TERMINAL
FIGURE 7. Output Terminal Panel
FIGURE 8. Duplex Receptacle Detail
120 Volt Recetacle
One GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle
is provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
The reset button is for the GFCI when the circuit is tripped.
Pressing the "Test Button" (See Figure 9) in the center of
this receptacle will check the GFCI function. The receptacle
should be tested at least once a month.
Figure 9. GFCI Test Button
PAGE 26 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA10SP3X OUTPUT TERMINAL
Output Terminal Panel Available Voltages
The DCA10SPX3 is a single phase generator only. It is
able to supply both 120 volt and 240 volt.
120V Hard Wire Hookup
The output terminal panel, when suppling single phase 120
volts, will provide two circuits available at 41.7 amps with
any two wires plus the ground. (See Figure 10 below.)
Maximum Amps
The DCA-10SPX3 can provide 41.7 amps at 120 or 240
volts. Do not exceed the maximum amps!
240V Hard Wire Hookup
The output terminal panel, when suppling single phase 240
volts, will provide one circuit available at 41.7 amps with
two wires plus the ground. (See Figure 11 below.)
Figure 10. Hard Wire Hook-up
for 120 Volt
Figure 11. Hard Wire Hook-up
for 240 Volt
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 27
DCA-10SPX3 — INSTALLATION
Outdoor Installation
Install the generator in a location where it is not exposed to
rain or sunshine. Make sure the generator is on a secure
level ground so that it cannot slide or shift around. Also
install the generator in a manner so the exhaust will not be
discharged in the direction of nearby homes.
The installation site must be away from excessive 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 cause excessive wear, to the engine parts and
the alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
CAUTION :
Generator Grounding
To prevent 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.
An electric shock is apt to happen when
vibrators are used. Pay close attention
to handling when operating vibrators and
always use rubber boots and gloves to
protect the body from electrical shock.
2
) or larger.
2. When grounding the generator (Figure 12) connect the
ground cable between the lock washer and the nut on
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to overheat.
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any diesel engine are
very poisonous if discharged in a closed room, but harmless
if allowed to mix with the outside air. If the generator is
installed indoors, you must make provisions from venting
the engine exhaust to the outside of the building.
DO NOT cover ventilation areas on the enclosure. Covering
the ventilation grids will cause the engine to overheat.
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
PAGE 28 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
DCA-10SPX3 — INSTALLATION
CAUTION :
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 29
Figure 12. Typical Generator Grounding Application
Always check local codes for
proper grounding codes and
laws.
DCA-10SPX3 — PRE-SETUP
General Inspection Prior to Operation
The DCA-10SPX3 generator has been thoroughly inspected
and accepted prior to shipment from the factory. However,
be sure to check for damaged parts or components, or loose
nuts and bolts, which could have occurred in transit.
Extension Cable
When electric power is to provided to loads (ie. power
tools) at a distance from the generator, extension cables
are 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 Table 6 (cable selection guide) as a guide for selecting
proper cable size.
Circuit Breaker
To protect the generator from an overload,
main
circuit breaker is provided to protect the UNV output
from overload. In addition a 2-pole, 20 amp
breaker is provided to protect the GFCI receptacle from
overload. Make sure to switch both circuit breakers to the
"OFF" position prior to starting the engine.
a 3-pole, 50 amp,
GFCI
circuit
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
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PAGE 30 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)
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