Multiquip DCA-15SPX3 User Manual

PARTS AND OPERATION MANUAL

MQ POWER

Model DCA-15SPX3

WHISPERWATT

GENERATOR

Revision #2 (09/03/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

ARAR

TS DEPTS DEP

TS DEP

ARAR

TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

SERSER

SER

SERSER 800/835-2551 or 310/537-3700 FAX: 310/638-8046

WW 800/835-2551, or 310/537-3700 FAX: 310/698-8046

MAINMAIN

MAIN

MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

VICE DEPVICE DEP

VICE DEP

VICE DEPVICE DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

ARAR

TMENTTMENT

TMENT

TMENTTMENT

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — 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 ..................................................................... 10

Trailer Safety Guidelines .................................... 11-16

Operation and Safety Decals ............................. 17-18

Specifications .......................................................... 19

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

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

Dimensions ............................................................. 22

Control Panel Description .................................. 24-25

Output Terminal Information .............................. 26-28

Installation .......................................................... 30-31

Pre-Setup ........................................................... 32-35

Load Application ..................................................... 36

Generator Start-up Procedure ........................... 37-38

Generator Shutdown Procedure ............................. 39

Maintenance ...................................................... 40-41

Generator Wiring Diagram ...................................... 42

Engine Wiring Diagram ........................................... 43

Troubleshooting (Engine) ................................... 44-44

Troubleshooting (Generator/Engine) ...................... 46

Explanation of Codes in Remarks Section.............. 48

Suggested Spare Parts ........................................... 49

MQ Power DCA-15SPX3 Portable Generator

Generator Assembly .......................................... 50-51

Control Box Assembly ........................................ 52-53

Output Terminal Assembly ................................. 54-55

Engine and Radiator Assembly .......................... 56-57

Battery Assembly ............................................... 58-59

Muffler Assembly ............................................... 60-61

Fuel Tank Assembly ........................................... 62-63

Enclosure Assembly ........................................... 64-67

Rubber Seals Assembly ..................................... 68-69

Operation and Safety Decal Locations .............. 70-71

Kubota V2203-D1-B Engine

Crankcase Assembly ......................................... 72-73

Oil Pan Assembly ............................................... 74-75

Cylinder Head Assembly .................................... 76-77

Gearcase Assembly ...........................................78-79

Main Bearing Case Assembly ............................ 80-81

Head Cover Assembly ....................................... 82-83

Inlet Manifold Assembly .....................................84-85

Exhaust Manifold Assembly ............................... 86-87

Valve & Rocker Assembly .................................. 88-89

Camshaft Assembly ...........................................90-91

Piston and Crankshaft Assembly .......................92-93

Flywheel Assembly ............................................94-95

Starter Assembly & Mounting ............................96-97

Starter (Components) Assembly ......................98-99

Nozzle Holder Assembly ............................... 100-101

Injection Pump 1 Assembly ........................... 102-103

Injection Pump 2 Assembly ........................... 104-105

Fuel Camshaft Assembly .............................. 106-107

Governor Assembly ...................................... 108-109

Speed Control Plate Assembly ..................... 110-111

Engine Stop Lever Assembly ........................ 112-113

Stop Solenoid Assembly ............................... 114-115

Alternator Assembly ...................................... 116-117

Alternator (Components) Assembly .............. 118-119

Fan Assembly................................................ 120-121

Water Flange & Thermostat Assembly ........ 122-123

Water Pump Assembly .................................. 124-125

Radiator Assembly ........................................ 126-127

Fuel Filter Assembly ..................................... 128-129

Terms and Conditions Of Sale — Parts ................ 130

PAGE 4 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

PARTS ORDERING PROCEDURES

■ 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

■ Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Get special freight allowances when you order 10 or more line items via FAX!**

■

UPS Ground Service at no charge for freight

■

PS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.

Extra Fax Discount

for Domestic USA

Dealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

CAUTION:

■

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

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.

before servicing engine or generator.

RULES FOR SAFE OPERATION

The following safety guidelines should always be used when operating the DCA-15SPX3 portable generator:

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, steeltoed boots and other protective devices required by the job.

■

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

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact 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

CAUTION:

■

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

hot

components can cause serious burns.

flow is restricted it will cause serious damage to the generator or engine and may

cause injury to people. Remember the generator engine gives off DEADLY carbon monoxide gas.

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

■

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.

PAGE 6 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO

smoke around or near the machine.

NOT

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

Topping-off to filler port is dangerous, as it tends to spill fuel.

bodily harm or even death.

RULES FOR SAFE OPERATION

CAUTION:

■

NEVER touch output terminals during operation. This is

Always stop the machine when contact

extremely dangerous. with the output terminals is required.

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.

2. Coolant Drain Plug - Removing the coolant drain plug

CAUTION:

3. Engine Oil Drain Plug - Removing the engine oil drain

■

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.

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-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 7

■

CAUTION:

NEVER Run engine without air filter. Severe engine damage

may occur.

Battery

■

Always service air cleaner frequently to prevent carburetor

■

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:

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.

RULES FOR SAFE OPERATION

■

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

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.

with a flame or spark, an explosion could occur.

■

Always drain fuel prior to lifting.

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 skinclothing or skin

clothing or skin

clothing or skinclothing or skin

, rinse skin or clothing

immediately with plenty of water.

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

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 ManualKubota Engine Owner's Manual

Kubota Engine Owner's Manual

Kubota Engine Owner's ManualKubota Engine Owner's Manual

for engine

PAGE 8 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

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

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

Also know the phone numbers of the nearest

doctordoctor

doctor

and

doctordoctor

. Know the location of the nearest telephone.

fire departmentfire department

fire department

fire departmentfire department

fire extinguisherfire extinguisher

fire extinguisher

fire extinguisherfire extinguisher

ambulanceambulance

ambulance

ambulanceambulance

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, and fuel filters. DO NOT use 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.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 9

■

Towing Safety Precautions

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

CAUTION :

■

ALWAYS make sure that the vehicle and trailer directional,

■

Check with your county or state safety towing regulations department before towing your generator.

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 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".

backup, brake, and trailer lights are connected and working properly.

■

The maximum speed (unless otherwise posted) for highway towing is 45 M.P.H.. Recommended off-road towing is not to exceed 10 M.P.H. 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.

DCA-15SPX3 — TOWING

chocked blocks

support blocks

tippingtipping

tipping

tippingtipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling rolling

rolling,

rolling rolling

Figure 1. DCA-15SPX3 and Towing Trailer

PAGE 10 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — TRAILER-SAFETY GUIDELINES

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 3 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-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 11

DCA-15SPX3 —TRAILER-SPECIFICATIONS

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W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

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PAGE 12 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 —TRAILER-SPECIFICATIONS

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DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 13

DCA-15SPX3 —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-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

Figure 2. Major Suspension Components

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TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

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DCA-15SPX3 — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN 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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NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 15

DCA-15SPX3 —TRAILER WIRING DIAGRAM

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 16 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-15SPX3 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-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 17

Machine Safety Decals

DCA-15SPX3 — OPERATION AND SAFETY DECALS

PAGE 18 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — SPECIFICATIONS

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DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 19

DCA-15SPX3 — GENERAL INFORMATION

DCA-15SPX3 3 FAMILIARIZATION Generator

genergener

The MQ Power Model DCA-15SPX3 is a 15 kW that has been 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)

15 kW Output Terminal (UNV)

Main Circuit Breaker 65 amps

GFCI Circuit Breaker 20 amps

AC Ammeter Indicator

AC Voltmeter Indicator

Output Voltage Adjustment Knob

Engine Warning Indicator

Engine Speed Control Lever

Hour Meter

Ground Ter minal

gener

genergener

atorator

ator

atorator

Open Delta Excitation System

The DCA-15SPX3 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

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

utomatic utomatic

utomatic

utomatic utomatic

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

" excitation system. The open delta

oltage Regulator oltage Regulator

oltage Regulator

oltage Regulator oltage Regulator

" and responds according the

(AVR) is supplied

The DCA-15SPX3 is powered by a 4-cylinder KUBOTA Model V2203 performance requirement for the generator. Reference Table 5, page 19 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.

The basic controls and indicators for the DCA-15SPX3 generator are addressed on the following pages.

diesel diesel

diesel

diesel diesel

engine. This engine is designed to meet every

PAGE 20 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — MAJOR COMPONENTS

Figure 4. DCA-15SPX3 Generator Major Components

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 21

DCA-15SPX3 — DIMENSIONS

Figure 5. Dimensions

PAGE 22 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

NOTE PAGE

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 23

DCA-15SPX3 — CONTROL PANEL

Figure 6. Control Panel

PAGE 24 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — CONTROL PANEL

The definitions below describe the controls and functions of the DCA-15SPX3 "

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 drawing from the generator.

3. AC Voltmeter – Indicates the single phase output voltage present at the U & V terminals.

4. Engine Warning Indicator- This engine warning indicator will notify possible damage before it occurs:

A. Oil Pressure - the light will go on during initial

start, but will go out once the engine is warm. If the oil pressure light comes on during operation, this may indicate critical low oil level.

B. Charge Light - This light indicates the battery is

not charging.

C. Water Temperature Light - This light indicates the

coolant temperature is abnormally high.

D. Engine Protection - This will shut down the engine

if there is an abnormal event that may have occurred. This prevents damage to the engine.

Control Panel Control Panel

Control Panel

Control Panel Control Panel

"(Figure 6).

12. Engine Speed Control Lever - This lever controls the speed of the engine speed from idle to high for maximum rpm.

13. Ground Terminal – If required this ground terminal is to be used in conjunction with the GFCI receptacle only.

14. AC Output Terminals – These three output terminals (UNV), provide the single phase output voltage to the load source. NEVER connect a load to these output terminals when the main circuit breaker is "ON" and the engine is running.

15. Voltage Adjust Control Knob – Used to adjust the generator's single phase output voltage at the UNV output terminals. This control knob is to be used in conjunction with the AC voltmeter.

16. Main Circuit Breaker – This three-pole, 65 amp main breaker is provided to protect the single phase UNV voltage output from overload.

5. Hour Meter – Indicates the amount of hours the generator has been in operational use.

6. GFCI Circuit Breaker – This single-pole, 20 amp breaker is provided to protect the 120 VAC GFCI receptacle from overload.

7. Starter Switch - This is to turn on and off the engine with a key.

8. CS6369 Receptacle - This locking type receptacle provides 240/120VAC single output voltage, for equipment not exceeding 50 amps.

9. 240 VAC Receptacle – Provides 240 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

10. 120 VAC Receptacle – Provides 120 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

11. 120VAC Receptacle (GFCI)- Provides 120 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 25

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

DCA-15SPX3 FAMILIARIZATION

The Output Terminal panel is provided with the following:

One GFCI 120 Volt Receptacle, 20 Amp (single-phase)

15 kW Output Terminal (UNV)

Ground Ter minal

Main Circuit Breaker 65 amps

GFCI Circuit Breaker 20 amps

120 Volt Receptacle

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.

Pressing the reset button resets the receptacle after being tripped. Pressing the "Test Button" (See Figure 7) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.

NEMA L5-30R Output Receptacle

The L5-30R receptacle supplies 30 amps at 120 volts. A 30 amp circuit breaker helps protect any load that it is feeding.

NEMA L6-30R Output Receptacle

The L6-30R supplies 30 amps at 240 volts. A 30 amp circuit breaker helps protect any load that it is feeding.

NEMA CS-6369 Output Receptacle

The CS-6369 supplies 50 amps at 120/240 volts. A 50 amp circuit breaker helps protect any load that it is feeding.

Connecting Load

Loads can be connected to the generator by the UNV Lugs or the duplex receptacle (See figure 3). Make sure to read the operation manual before attempting to connect a load to the generator.

Circuit Breakers

The DCA-15SPX3 has a main 65 amp circuit breaker and receptacle circuit breakers that are listed above. The main purpose of the circuit breakers is to protect the load the generator is powering.

Figure 7. GFCI Test Button

Maximum Output

The entire load connected to the UNV Lugs and both slots in the duplex receptacle must not exceed 16.5 kW in standby or 15 kW in prime output.

Maximum Amps

The generator will provide a maximum total amps of 62.5.

Do not exceed the maximum allowed amperage!

PAGE 26 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

Figure 8. Receptacle Location on

Generator

Figure 9. Receptacle Details

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 27

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

120V Hard Wire Hookup

The output terminal panel, when suppling single phase 120 volts, will provide two circuits available at 62.5 amps with any two wires plus the ground. (See Figure 10 below.)

240V Hard Wire Hookup

The output terminal panel, when suppling single phase 240 volts, will provide one circuit available at 62.5 amps with two wires plus the ground. (See Figure 11 below.)

Figure 10. Hard Wire Hookup

for 120 Volt

Figure 11. Hard Wire Hookup

for 240 Volt

NOTE

When using plural single phase voltages, make sure to balance the load on each of the single phase legs.

PAGE 28 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

NOTE PAGE

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 29

DCA-15SPX3 — INSTALLATION

Outdoor Installation

Install the generator in a location where it will not be exposed to rain or sunshine. 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 the engine and alternator parts.

CAUTION :

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

Indoor Installation

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.

CAUTION :

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

2. When grounding the generator (Figure 12) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

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

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 insulate the body from electrical shock.

NOTE

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

DO NOT cover ventilation areas on the enclosure. Covering the ventilation grids will cause the engine to overheat.

PAGE 30 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

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