Multiquip DCA-15SPX4 User Manual
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATT
TM
SERIES
MODEL DCA-15SPX4
60 Hz GENERATOR
Revision #0(02/17/09)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
NOTE PAGE
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 3
TABLE OF CONTENTS
MQ POWER DCA-15SPX4MQ POWER DCA-15SPX4
MQ POWER DCA-15SPX4
MQ POWER DCA-15SPX4MQ POWER DCA-15SPX4
TMTM
TM
WHISPERWHISPER
WHISPER
WHISPERWHISPER
California Proposition 65 Warning ..................................... 2
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 ........................................... 10-14
Installation ................................................................. 16-17
General Information ........................................................ 18
Major Components ......................................................... 19
Generator Control Panel ............................................ 20-21
Output Terminal Panel Familiarization ........................ 22-24
Load Application/Max Amperage .................................... 25
Gauge Reading/Terminal Panel Connections .................. 26
Setup ......................................................................... 27-30
Generator Start-up Procedure ................................... 31-32
Generator Shut-Down Procedure .................................... 33
Maintenance (Engine) ................................................ 34-36
Maintenance (Trailer) ................................................. 37-39
Generator Wiring Diagram ............................................... 40
Engine Wiring Diagram ................................................... 41
Troubleshooting (Engine) ........................................... 42-43
Troubleshooting (Generator) ............................................ 44
Troubleshooting (Pre-Heat Lamp Codes) ........................ 45
Explanation of Code in Remarks Column ....................... 46
Suggested Spare Parts .................................................. 47
WW
W
WW
AA
A
AA
TTTT
TT
TTTT
TMTM
GENERATORGENERATOR
GENERATOR
GENERATORGENERATOR
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly .................................................. 48-49
Control Panel Assembly ............................................ 50-53
Output Terminal Assembly ......................................... 54-55
Engine and Radiator Assembly ................................. 56-59
Battery Assembly ...................................................... 60-61
Muffler Assembly ...................................................... 62-63
Fuel Tank Assembly .................................................. 64-65
Enclosure Assembly ................................................. 66-69
Rubber Seals Assembly ............................................ 70-71
Nameplate and Decals .............................................. 72-73
Terms and Condition of Sale — Parts ............................ 74
Specification and part
NOTE
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
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
on
Standard orders
Domestic (US) Dealers Call:
International Customers
their local Multiquip Representatives for
and qualify for a 5% Discount
for all orders which include
for all orders which include
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
should contact
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
❒❒
❒
❒❒
www.mqpower.com
When ordering parts, please supply:
❒❒
❒
Specify Preferred Method of Shipment:
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!
❒❒
✓
UPS/Fed Ex
■
■
■ Next Day
Standard Orders
Priority One
Ground
✓ DHL
✓
Truck
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 5
DCA-15SPX4 — SPECIFICATIONS
ledoM4XPS51-ACD
snoitacificepSrotareneG.1elbaT
epyT
esahP
tuptuOybdnatS
tuptuOemirP
egatloV
ycneuqerF
deepS
rotcaFrewoP
.xuA
6L(
rewoPCA
)ICFG(
rewoPCA.xuA
)R03-5L(
rewoPCA.xuA
)R03-
rewoPCA.xuA
)9636SC(
K6
elgniS
rotareneg
eriW-3esahP
WK5.61
WK51
021/V042
zH06
mpr0081
0.1
zH06,esahPelgniSCAV021@WK4.2
zH06,esahPelgniSCAV021@WK6.3
zH06,esahPelgniSCAV042@WK2.7
zH06,esahPelgniSCAV042@WK21
zH06,esahPelgniSCAV021@W
suonorhcnysepytdetcetorpnepo,detalitnevfles,dleifgnivloveR
snoitacificepSenignE.2elbaT
ledoM
epyT
srednilyCfo.oN
oB
ekortSxer
tuptuOdetaR
tnemecalpsiD
gnitratS
yticapaCtnalooC
yticapaCliOebuL
yticapaCknaTleuF
tarh/)L2.5(.lag73.1 daollluf tarh/)L80.4(.lag80.1 daol4/3
noitpmusnoCleuF
tarh/)L41.3(.lag38.0 daol2/1 ta
yrettaB
leuF
thgieWyrD
lE
.61
M-3022VATOBUK
epytrebmahcnoitsubmoclriws,delooc-retaw,elcyC4
srednilyc4
)mm4.29xmm78(.ni46.3x.ni34.3
mpr0081/PH1.72
)cc791,2(.ni.uc1.431
cirtce
)sretil9.7(.lag90.2
)sretil6.7(.lag00.2
)sretil26(.lag4
rh/)L43.2(.lag26.0 daol4/1
)A525:72(HA56-V21
leuFleseiD2#
gk775
thgieWlatoT
gk946
PAGE 6 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
TOP VIEW
DCA-15SPX4 — DIMENSIONS (TOP, SIDE AND FRONT)
A
Figure 1. Dimensions
SIDE VIEW
FRONT VIEW
15
WHISPERWATT
B
MQPOWER
D
C
SNOISNEMID.3ELBAT
UNV
E
Denyo
A).mm055(.ni56.12
retteLecnerefeR).mm(.tfnoisnemiD
B).mm094(.ni92.91
C).mm516(.ni12.42
F
D).mm514,1(.ni07.55
E).mm
209.ni15.53
F).mm056(.ni06.52
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 7
DCA-15SPX4 — 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-15SPX4
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
Diesel fuel
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-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
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!
DCA-15SPX4 — 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)
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 9
DCA-15SPX4 — 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-15SPX4 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 generator 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-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — 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 6.
stand in water
while AC power from the generators
lay in wate
r.
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
by electrocution can result from operating an
National Electrical Code
(NEC) and
injury
Maintenance Safety
■
■
■
■
■
■
■
■
■
■
■
■
■
or
■
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
as an electrical ground.
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 11
1
DCA-15SPX4 — 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
or
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-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — RULES FOR SAFE OPERATION
ACCIRCUIT
B
REAKER
OFF
22
A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
OFF
22A
120
V
20A
120V
OFF
ON
GA-2.9R
ACCIRCUIT
BREAKER
OF
F
2
2
A
120
V
20A
120V
OFF
ON
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
or
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
F
A
F
2
O
2
ACCIRCUIT
120V
2900
F
A
F
2
O
2
ACCIRCUIT
BREAKER
NEVER use inside a home
or garage, even if doors
and windows are open
Avoid other generator hazards.
2900
GA-2.9R
F
A
F
2
O
2
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
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 13
DCA-15SPX4 — 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-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
NOTE
For more saftey tips, see the trailer saftey
guidelines section in this manual.
NOTE PAGE
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 15
DCA-15SPX4 — INSTALLATION
Figure 2. Typical Generator Grounding Application
PAGE 16 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — 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 2) 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.
2
) 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.
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 17
DCA-15SPX4 — GENERAL INFORMATION
DCA-15SPX4 Whisperwatt™ Series Familiarization
Generator
The MQ Power Model DCA-15SPX4 is a 15 kW
generator
(Figure 3) that is designed as a high quality portable (requires
Open Delta Excitation System
The generator is equipped with the state of the art "
Delta
" excitation system. The open delta system consist of
an electrically independent winding wound among stationary
windings of the AC output section.
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other industrial
and construction machinery.
Generator Control Panel
The “Engine Operating Panel” is provided with the following:
■■
Warning Lamp Unit
■
■■
■■
■
Preheat Lamp
■■
■■
■
Oil Pressure Alarm Lamp
■■
■■
Water Temperature Alarm Lamp
■
■■
■■
■
Battery Charging Alarm Lamp
■■
■■
■
Speed Control Switch
■■
■■
■
Frequency Meter (Hz)
■■
■■
■
AC Ammeter (Amps)
■■
■■
■
AC Voltmeter (Volts)
■■
■■
■
Voltage Regulator
■■
■■
■
Starter Switch
■■
■■
■
Hour Meter
■■
■■
■
3-Pole, 70 amp Main Circuit Breaker
■■
■■
■
1-Pole, 20 amp Circuit Breaker (for GFCI)
■■
■■
■
1-Pole, 30 amp Circuit Breaker (for L5-30R)
■■
■■
■
2-Pole, 30 amp Circuit Breaker (for L6-30R)
■■
■■
■
2-Pole, 50 amp Circuit Breaker (for CS6369)
■■
■■
■
“Control Box” (located behind the Gen. Control Panel)
■■
■■
■
Automatic Voltage Regulator
■■
■■
■
Current Transformer
■■
■■
■
Over-Current Relay
■■
■■
■
Voltage Rectifer
■■
■■
■
Starter Relay
■■
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
■■
■
Three output terminal lugs (1Ø power)
■■
■■
■
1-Phase Output Terminal
■■
■■
■
120/240V output receptacle (CS-6369), 50A
■■
■■
■
120 output receptacle (5-20R)GFCI, 20A
■■
■■
■
120V output receptacle (L5-30R), 30A
■■
■■
■
240V output receptacle,(L6- 30R) 30A
■■
■■
■
Ground Terminal (for G.F.C.U)
■■
■■
■
Battery Charger (Optional)
■■
■■
■
Water Heater (Optional)
■■
There are four connections of the open delta A, B, C and D.
During steady state loads, the power from the voltage regulator
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases of the voltage input to the
voltage regulator are then rectified and are the excitation
current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the voltages
of each phase to provide higher excitation to the exciter
section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load.
Engine
The DCA-15SPX4 is powered by a 4 cylinder, water cooled,
Kubota Model V2203-M diesel engine
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.
fixed ceiling
" and responds
. This engine is
Open-
PAGE 18 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — MAJOR COMPONENTS
4elbaT. stnenopmoCrojaMrotareneG
.ONMETINOITPIRCSED
1ylbmessAretliFriA
2ylbmessArelffuM
3ylbmessArotaidaRdnaenignE
Figure 3. Major Components
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 19
4ylbmessArotareneG
5ylbmessAyr
6ylbmessAknaTleuF
7ylbmessAlenaPlortnoCrotareneG
8ylbmessAelcatpeceRtuptuO
9ylbmessAlanimreTtuptuO
ettaB
1
DCA-15SPX4 — GENERATOR CONTROL PANEL
A
V
HZ
WATERTEMP.
OILPRESS.
BATT.LOWLEVEL
DECREASE
INCREASE
PREHEATLAMP
19
18
17
16
15
U
N
14
1
V
2
13
3
12
11
4
BATT.LOWLEVEL
10
PREHEATLAMP
5
6
7
8
9
Figure 4. Generator Control Panel
PAGE 20 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
Generator Control Panel
the
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. Engine Warning Lamp Module – This module displays
the following engine failures:
A. Pre-Heat Lamp – As the engine cranks, this lamp
will illuminate to indicate automatic preheating of the
engine. When the lamp turns off, the engine has been
preheated.
B. Water Temperature Alarm Lamp – This lamp
indicates when the emergency shutdown system has
stopped the engine for abnormally high water
temperature(234 deg. F).
C. Oil Pressure Alarm Lamp – This lamp is on when
the starter switch is in the “ON” position and the engine
oil pressure is low(7.1 PSI). It will indicate when the
starter switch is in the “ON” position, before the engine
has been started, and if the emergency shutdown
system has stopped the engine.
D. Battery Charging Alarm Lamp – This lamp is ON
when the output voltage of the alternator drops tob an
unusual value. If this lamp indicates during operation,
the emergency shutdown system immediately operates
to stop the engine.
5. Hour Meter – Indicates the number of hours machine
has been in use.
6. Engine Speed Control Switch – This switch controls
the speed of the engine from
7. Starter Switch – This switch has four positions.
(Figure 4).
idle
to high.
.
C. Preheat – Use this position before starting during
cold weather operating conditions. Observe the Preheat
Lamp for indication of the proper time for starting the
engine.
D. Start – This position starts the engine, and when
released will automatically return to the run position.
8. Voltage Regulator Control – Allows ±15% manual
adjustment of the generator’s output voltage.
9. CS6369 Receptacle – Provides 240/120 VAC output
(50 amps max).
10. L6-30R Receptacle – Provides 240 VAC output (30
amps max).
11. L5-30R Receptacle – Provides 120 VAC output (30
amps max).
12. GFCI Receptacle – Provides 120 VAC output (20 amps
max).
13. AC Circuit Breaker - This two-pole, 50A breaker is
provided to protect the CS6369 receptacle from overload.
14. UNV Terminals - Connect load to these terminals AC
load for 120/240 VAC single phase 60 Hz. output.
15. GFCI Ground Terminal - Use this terminal to ground
the generator
16. AC Circuit Breaker - This two-pole, 30A breaker is
provided to protect the auxillary receptacle (for L6-30R)
from overload.
17. AC Circuit Breaker - This single-pole, 30A breaker is
provided to protect the auxillary receptacle (for L5-30R)
from overload.
18. AC Circuit Breaker - This single-pole, 20A GFCI breaker
is provided to protect the GFCI receptacle (5-20R) from
overload.
19. AC Circuit Breaker – This three-pole, 70A main breaker
is provided to protect the the
Terminal Lugs
U,N, and V Output
from overload.
A. Stop – The switch should be in this position anytime
the unit is not in operation. This position allows removal
of the key.
B. Run – The switch should be in this position when
the unit is in operation.
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 21
1
DCA-15SPX4 — OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
The
Output Terminal Panel
(Figure 5) 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:
■■
■
CS6369 receptacle 125/240V@ 50 amps
■■
lugs.
■■
■
Circuit Breaker @ 50 amps (CS6369 receptacle)
■■
■■
120V GFCI receptacle @ 20 amps
■
■■
■■
L5-30R receptacle, 125V @ 30 amps
■
■■
■■
■
L6-30R receptacle, 240V @ 30 amps
■■
■■
■
Three Output Terminal Lugs ( U, N, V and Ground)
■■
” (Figure 5) is provided with the
Figure 5. Output Terminal Panel
PAGE 22 — DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09)
DCA-15SPX4 — OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacle
This120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacle
can be used anytime the generator is in operation. Remember
the load output (current) of the GFCI receptacle is dependent
on the load requirements of the U, N, and V output terminal
lugs.
Pressing the
being tripped. Pressing the
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
reset
button resets the GFCI receptacle after
Test Button
(See Figure 6) in
L5-30R Twist Lock 120 VAC Receptacle
There is one L5-30R, 120 VAC 30 amp auxilliary twist-lock
receptacle (Figure 8) provided on the output terminal panel.
L6-30R Twist Lock 240 VAC Receptacle (Option)
There is one L6-30R, 240 VAC 30 amp auxilliary twist-lock
receptacle (Figure 9) provided on the output terminal panel.
Figure 8. 120 VAC L5-30R Twist-Lock
Auxiliary Receptacle
Figure 6. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacle (Option)
There is one CS-6369 120/240V, 50 amp auxilliary twist-lock
receptacle (Figure 7) provided on the output terminal panel.
This receptacle is protected by a 50 amp circuit breaker.
CS-6369
TWIST-LOCK
RECEPTACLE
Turn the
control panel to obtain the desired voltage. Turning the knob
SINGLE-PHASE
120/240 VAC
50 AMP OUTPUT
Figure 7. 120/240V CS6369 Twist-Lock
Auxiliary Receptacle
clockwise will
clockwise will
Figure 9. 240 VAC L6-30R Twist-Lock
Auxiliary Receptacle
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
(Figure 10) on the
Figure 10. Voltage Regulator Control Knob
1
DCA-15SPX4— OPERATION MANUAL — REV. #0 (02/17/09) — PAGE 23
Loading...