Multiquip DCA20SPXU2 User Manual

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Page 1

OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA20SPXU2

60HZ GENERATOR

(ISUZU BV-4LE2 DIESEL ENGINE)

Used with MLt20 series Light towers onLy

PARTS LIST NO. M1870301404

Revision #0 (01/18/13)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PN 49840

Page 2

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 3

REPORTING SAFETY DEFECTS

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

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

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

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

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

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 3

Page 4

TABLE OF CONTENTS

DCA20SPXU2 60 Hz Generator

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

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

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

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

Safety Information ..............................................6-11

Speciﬁcations ........................................................ 12

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

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

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

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

Generator Control Panel ........................................ 18

Engine Control Panel ........................................ 20-21

Output Terminal Panel Familiarization .............. 22-24

Load Application/Generator Output ....................... 25

Output Terminal Panel Connections ...................... 26

Inspection/Setup ............................................... 27-30

Generator Start-Up Procedure (Manual) ......... 31-32

Generator Start-Up Procedure (Auto) ................... 33

Generator Shut-Down Procedures ........................ 34

Maintenance ..................................................... 35-38

Trailer Maintenance .......................................... 39-42

Trailer Wiring Diagram ........................................... 43

Generator Wiring Diagram ..................................... 44

Engine Wiring Diagram .......................................... 45

Troubleshooting (Generator) .................................. 46

Explanation Of Code In Remarks Column............. 48

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

Component Drawings

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

Control Box Assembly. ...................................... 52-55

Engine And Radiator Assembly ........................ 56-59

Output Terminal Assembly ................................ 60-61

Battery Assembly.............................................. 62-63

Mufﬂer Assembly .............................................. 64-65

Fuel Filter Assembly ......................................... 66-67

Enclosure Assembly ......................................... 68-71

Rubber Seals Assembly ................................... 72-73

Nameplate and Decals Assembly .................... 74-75

Terms And Conditions Of Sale — Parts ................ 76

PAGE 4 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 5

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

If you have an MQ Account, to obtain a Username

Effective:

Choose from three easy options:

January 1st, 2006

Best Deal!

Order via Internet (Dealers Only):

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

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁ cation Information

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: 1-800-6-PARTS-7 (800-672-7877)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

and Password, E-mail us at: parts@multiquip.

com.

To ob tai n a n M Q Acc oun t, co n ta ct yo u r 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

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!

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 5

Page 6

SAFETY INFORMATION

Do not operate or service the equipment before reading the

Potential hazards associated with the operation of this

entire manual. 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.

SAFETY MESSAGES

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

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Indicates a hazardous situation which, if not avoided,

COULD result in DEATH or SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 6 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 7

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

ensure generator is on level ground before use.

keep the machine in proper running condition.

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 unauthorized personnel

CAUTION

 NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

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

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

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

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

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

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

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

bodily harm or even death.

WARNING

NOTICE

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

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

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

 NEVER disconnect any

These devices are intended for operator safety.

devices will void all warranties.

CAUTION

 NEVER lubricate components or attempt service on a

running machine.

NOTICE

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 7

Page 8

ENGINE SAFETY



NOTICE

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

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

Wet stacking is a common problem with diesel engines

no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow

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

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

applied to relieve the condition. It can reduce the system

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed

from the engine exhaust. Spark arresters are qualiﬁ ed

SAFETY INFORMATION

DANGER

 The engine fuel exhaust gases contain poisonous carbon

monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

 DO NOT place han ds or fingers inside en g ine

compartment when engine is running.

 NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

DO NOT remove the radiator cap while the

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

 DO NOT remove the coolant drain plug while the engine

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

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

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



which are operated for extended periods with light or

unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

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.

 State Health Safety Codes and Public Resources

 DO NOT remove the engine oil drain plug while the

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

CAUTION

NEVER touch the hot exhaust manifold,

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

PAGE 8 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

to prevent accidental discharge of sparks or ﬂ ames

and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

Page 9

FUEL SAFETY

DANGER

 Make sure the hitch and coupling of the towing vehicle

NEVER

tow a trailer with defective hitches, couplings, chains, etc.

Trailer tires should be inﬂ ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,

Trailer should be adjusted to a level position at all times

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

SAFETY INFORMATION

are rated equal to, or greater than the trailer “gross vehicle weight rating.”

 DO NOT start the engine near spilled fuel or combustible

ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

 ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

 ALWAYS use extreme caution when working with

ﬂ ammable liquids.

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

or hot.

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

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

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

 NEVER use fuel as a cleaning agent.

 DO NOT smoke around or ne a r the

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

TOWING SAFETY

 Check with your local county or state safety

towing regulations, in addition to meeting

Depar tment of Transpor tation (DOT) Safety Towing Regulations, before towing

your generator.

 Refer to MQ Power trailer manual for additional safety

information.

 In order 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 mechanically sound and in good operating condition.

 ALWAYS shutdown engine before transporting

CAUTION

 ALWAYS inspect the hitch and coupling for wear.

 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

chain.

 ALWAYS properly

vehicle.

 ALWAYS

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

 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

exceed 15 MPH or less depending on type of terrain.



or jack-kniﬁ ng. Smooth, gradual starts and stops will improve towing.

 Avoid sharp turns to prevent rolling.



when towing.

 Raise and lock trailer wheel stand in up position when

towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 9

Page 10

ELECTRICAL SAFETY

DANGER



 Make sure power cables are securely connected to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

DO NOT touch output terminals during

operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

The electr ical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

NEVER insert any objects into the output

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

Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

SAFETY INFORMATION

generator’s output receptacles. Incorrect connections may cause electri cal sh ock and damage to the generator.

NOTICE

 ALWAYS

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water while AC power from the

generator is being transferred to a load.

 NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

PAGE 10 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 11

SAFETY INFORMATION

BATTERY SAFETY

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

DANGER

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

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

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

WARNING

 ALWAYS wear safety glasses when handling

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

 Use well-insulated gloves when picking up the battery.

 ALWAYS keep the battery charged. If the battery is not

charged, combustible gas will build up.

 ALWAYS recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration of combustible gasses.

NOTICE

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to

dispose of hazardous waste.

 DO NOT

down a drain or into any water source.

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

 If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 11

Page 12

Model

Type

Armature Connection

Phase

Standby Output

Prime Output

SPECIFICATIONS

Table 1. Generator Speciﬁcations

DCA-20SPXU2

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

Series

Single-Phase 3-Wire

22 kW (27.5 kVA)

20 kW (25.0 kVA)

Voltage

Frequency

Speed

Power Factor

Aux. AC Power

Sound Level db (A) full Load

at 23 ft. (7 meters)

Weight (No Fuel)

Weight (Fuel)

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

120/240V

60 Hz

1800 rpm

1.0

Single Phase, 60 Hz

1,412 lbs. (640 kg.)

2,012 lbs. (913 kg.)

Table 2. Engine Speciﬁcations

ISUZU BV-4LE2 Tier 4i

4 cycle, water-cooled, direct injection, turbo-charged

4 cylinders

3.34 in. x 3.77 in. (85 mm x 96 mm)

133 cu. in. (2,179 cc)

34.3 HP/1800 RPM

Electric

1.74 gal. (6.6 liters)

2.25 gal. (8.5 liters)

#2 Diesel Fuel, Low Sulfur Diesel Fuel Only

100 gal. (379 liters)

1.66 gal. (6.3 L)/hr at full load 1.21 gal. (4.6 L)/hr at 3/4 load

0.85 gal. (3.2 L)/hr at 1/2 load 0.58 gal. (2.2 L)/hr at 1/4 load

12V 53Ah x 1

PAGE 12 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 13

DIMENSIONS

TOP VIEW

SIDE VIEW

FRONT VIEW

Denyo

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 21.06 in. (535 mm.) F 72.83 in. (1,850 mm.)

B 21.06 in. (535 mm.) G 39.37 in. (1,000 mm.)

C 24.21 in. (615 mm.) H 29.53 in. (750 mm.)

D 26.38 in. (670 mm.)

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

E 25.00 in. (635 mm.)

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 13

Page 14

GENERATOR GROUND LUG

GROUND CABLE

INSTALLATION

GROUND ROD FOR EARTH GROUND. CONNECT TO BUILDING GROUND IF APPLICABLE

REFERENCE NEC 250-83 (C)

8’ (MINIMUM)

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 15

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

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

GENERATOR GROUNDING

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

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 - 8 AWG (5.3 mm2) or larger.

b. Aluminum - 6 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.

INDOOR INSTALLATION

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

MOUNTING

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

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

NOTICE

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

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 15

Page 16

GENERAL INFORMATION

GENERATOR

The MQ Power Model DCA20SPXU2 generator (Figure 3) is a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industr ial and construction machinery.

ENGINE PANEL

 Panel Light  Panel Light Switch  Fuel Filter Water Level Alarm Lamp  Auto ON/OFF Engine Controller (MPEC) Switch  Fuel Guage  Oil Pressure Gauge  Water Temperature Guage  Tachometer Guage  Charging Ammeter Guage

GENERATOR CONTROL PANEL

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

 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltage Regulator  3-Pole, 90 amp Main Circuit Breaker  “Control Box” (located behind the Gen. Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

OUTPUT TERMINAL PANEL

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

 Two 120/240V output receptacles (CS-6369), 50A  Two auxilliary circuit breakers, (for CS-6369), 50A  Two 120V output receptacles (GFCI), 20A  Two GFCI circuit breakers, 20A  Four output terminal lugs (1Ø power)  Battery Charger (Optional)  Water Heater (Optional)

OPEN DELTA EXCITATION SYSTEM

This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectiﬁed and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the conﬁguration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “ﬁxed ceiling” and responds according the demands of the required load.

ENGINE

This generator is powered by a 4 cylinder, water cooled, direct injection, Izuzu Model BV-4LE2 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 for engine speciﬁcations.

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

ELECTRIC GOVERNOR SYSTEM

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

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.

PAGE 16 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 17

MAJOR COMPONENTS

AUTO

MANUAL

OFF/RESET

LOW OILPRESSURE

HIGH COOLANTTEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

O V

7 6

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Output Terminal Assembly

2 Output Receptacles Assembly

3 Mufﬂer Assembly

4 Air Filter Assembly

5 Battery Assembly

6 Generator Assembly

7 Engine Assembly

8 Circuit Breaker Assembly

9 Engine Control Panel Assembly

10 Generator Control Panel Assembly

Figure 3. Major Components

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 17

Page 18

GENERATOR CONTROL PANEL

INCREASE

DECREASE

OFF

Figure 4. Generator Control Panel

he deﬁnitions below describe the controls and functions of the Generator Control Panel (Figure 4).

1. Main Circuit Breaker—This three-pole, 90A main breaker is provided to protect the the U,O, and V Output Terminal Lugs from overload.

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

20001000

3000

RPM

AUTO

MANUAL

OFF/RESET

LOW OILPRESSURE HIGH COOLANTTEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.

The Control Box is equipped with the following major components:

 Over-Current Relay

3. Ammeter Change-Over Switch — This switch allows the AC ammeter to indicate the current ﬂowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the

 Automatic Voltage Regulator (AVR)

 Starter Relay

 Current Transformer

generator output in any fashion, it is for current reading only.

 Engine Controller

4. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz.

5. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

6. AC Voltmeter — Indicates the output voltage present at the U,O, and V Output Terminal Lugs.

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Page 19

NOTES PANEL

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 19

Page 20

ENGINE CONTROL PANEL

INCREASE

DECREASE

OFF

AUTO

MANUAL

OFF/RESET

LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

20001000

3000

Figure 5. Engine Control Panel

RPM

PAGE 20 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 21

ENGINE CONTROL PANEL

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

Oil Pressure Gauge — During normal operation this gauge should read between When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

35 to 65 psi. (241~448 kPa).

2. Water Temperature Gauge — During normal operation this

gauge be should read between

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

180°~221°F (82°~105°C)

4. Fuel Gauge — Indicates amount of diesel fuel available.

5. Tachometer — Indicates engine speed in RPM’s for 60

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

6. Panel Light — Normally used in dark areas or at night

time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

7. Panel Light Switch — When activated will turn on control

panel light.

8. Fuel Filter Water Level Alarm Lamp — This lamp will

illuminate when water in the fuel ﬁlter has reached an abnormal level.

9. Au t o S TART /S TO P E ng in e

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

Also the engine controller will shut down the engine in

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

A. MPEC Control Switch — This switch controls the

running of the unit. If this switch is set to the OFF/ RESET position, the unit will not run. When this switch is set to the manual position, the generator will start immediately.

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

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

B. Low Oil Pressure — Indicates the engine pressure

has fallen below 15 psi (103 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.

C. High Coolant Temperature — Indicates the engine

temperature has exceeded 230°F (110°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.

D. Overcrank Shutdown — Indicates the unit has

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

E. Overspeed Shutdown — Indicates the engine is

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

F. Engine Running — Indicates that engine is running

at a safe operating speed.

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

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

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 21

Page 22

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 7) 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 lugs.

NOTICE

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

SINGLE PHASE

240 -120 VAC

OUTPUT TERMINALS

RED

BLACK

WHITE

OUTPUT TERMINAL FAMILIARIZATION

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

 Two 120/240V output receptacles @ 50 amp

 Two Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two GFCI Circuit Breakers @ 20 amps

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

GROUND

TERMINAL

HARD WIRE

HOOKUP PANEL

GREEN

LOCK RECEPTACLES

120 VAC, 20 AMP

GFCI RECEPTACLES

RECEPTACLE

AND

CIRCUIT BREAKER

PANEL

CIRCUIT BREAKERS FOR CS-6369 TWIST

NEUTRAL

TERMINAL

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

AUX. POWER RECEPTACLES

120/240V, 50 AMPS

TWIST-LOCK

MQ POWER

CS-6369

ACCESS DOOR

LIFT TO OPEN

Figure 6. Output Terminal Panel

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Page 23

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, O, and V output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

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

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

Figure 9. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

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

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

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are two 120/240V, 50 amp auxiliary twist-lock (CS-

6369) receptacles (Figure 8) provided on the output terminal panel..

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

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

Figure 10. Plastic Face Plate (Output Terminal Lugs)

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 23

Page 24

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 90A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An over current relay (Figure 12) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 12. Over Current Relay

Figure 11. Connecting Loads

NOTICE

When connecting a load to the generator ALWAYS

make sure the load has an ON/OFF switch. DO NOT use the circuit breakers on the generator as a method of turning the load ON and OFF.

PAGE 24 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 25

LOAD APPLICATION/GENERATOR OUTPUT

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

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

Table 5. Power Factor By Load

NOTICE

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

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

 When connecting a resistance load such as an

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

 When connecting a ﬂuorescent or mercury lamp, a

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

 When connecting an electric drill or other power tools,

pay close attention to the required starting current capacity.

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

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

1.0

Common power tools 0.8

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

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

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

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

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

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

Generator Amperage

Table 7 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.

Table 7. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt 83 X 2 amps (4 wire)

1Ø 240 Volt 83 amps (4 wire)

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 25

Page 26

OUTPUT TERMINAL PANEL CONNECTIONS

UOV TERMINAL OUTPUT VOLTAGES

240/120V outout voltages can be obtained using the output terminal lugs.

The voltage regulator (VR), Figure 14 allows the user to increase or decrease the selected voltage.

1Ø-240 Output Terminal Voltage

1. Connect the load wires to the output terminal lugs as shown in Figure 13.

1Ø-120 Output Terminal Voltage

1. Connect the load wires to the output terminal lugs as shown in Figure 15.

Figure 15. Output Terminal Lugs

1Ø-120 Volt Connections

2. Turn the voltage regulator knob (Figure 14) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

Figure 13. Output Terminal Lugs

1Ø-240 Volt Connections

2. Turn the voltage regulator knob (Figure 14) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required.

Figure 14. Voltage Regulator Knob

NOTICE

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

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Page 27

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 90 amp, main circuit breaker is provided to protect the U,O and V Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Two 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

LUBRICATION OIL

Fill the engine crankcase with lubricating oil through the ﬁller hole, but DO NOT overﬁll. Make sure the generator is level and verify that the oil level is maintained between the two notches (Figure 16) on the dipstick. See Table 8 for proper selection of engine oil.

FUEL CHECK

DANGER

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

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 17). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

Figure 16. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and reﬁll with the speciﬁed amount of oil as outlined in the ISUZU Engine Owner’s Manual. Oil should be warm before draining.

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

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

Table 8. Recommended Motor Oil

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after ﬁlling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

FUEL TANK

FILLER NECK

Figure 17. Trailer Fuel Tank

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 27

Page 28

INSPECTION/SETUP

Refueling Procedure:

WARNING

Diesel fuel and its vapors are dangerous

to your hea lth and the surro unding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks — Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 18).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

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

2. Remove fuel cap from ﬁller neck and ﬁll fuel tank (Figure 19).

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 19).

Figure 19. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 20).

Figure 18. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel when refueling.

Figure 20. Fuel Expansion

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

ISUZU recommends antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the ISUZU

Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

PAGE 28 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 29

INSPECTION/SETUP

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 9 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

Table 9. Coolant Capacity

Engine and Radiator 1.74 gal (606 liters)

Reserve Tank 0.26 gal. (1 liter)

Operation in Freezing Weather

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

Table 10. Anti-Freeze Operating Temperatures

Vol %

Anti-

Freeze

50 -37 -34 108 226

Freezing Point Boiling Point

°C °F °C °F

damage and wear and adjust it in accordance with the

ISUZU Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 21) when depressed with the thumb as shown below.

Figure 21. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan while the generator set is running.

BATTERY

NOTICE

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

CLEANING THE RADIATOR

The engine may overheat if the radiator ﬁns become overloaded with dust or debris. Periodically clean the radiator ﬁns with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect it in accordance with the ISUZU Engine Owner’s Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to insufﬁcient charging of the battery. Inspect the fan belt for

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

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the ter minals fir mly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

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

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

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 29

Page 30

INSPECTION/SETUP

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 22) are

properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

Figure 22. Battery Connections

When connecting battery do the following:

ALTERNATOR

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

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

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

1. NEVER connect the battery cables to the battery terminals when the Control Power Switch is in either the ON position. ALWAYS make sure that the Control Power Switch is in the OFF position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

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

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Page 31

GENERATOR START-UP PROCEDURE (MANUAL)

INCORRECT

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers

(Figure 23) in the OFF position prior to star ting the engine.

STARTING (MANUAL)

1. Place the MPEC control switch in the MANUAL position to start the engine (Figure 25) position.

AUTO

OFF/RESET

Figure 25. MPEC Control Switch

(Manual Position)

2. Verify that the engine running status LED on the MPEC module (Figure 26) is lit (ON) after the engine has started

AUTO

OFF/RESET

LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

MANUAL

Figure 23. Main, Aux. and GFCI

Circuit Breakers (OFF)

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

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

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

4. Close all engine enclosure doors (Figure 24).

CORRECT

Figure 26. Engine Running (LED ON)

3. The generator’s frequency meter (Figure 27) should be displaying the 60 cycle output frequency in HERTZ.

Figure 27. Frequency Meter

4. The generator’s AC-voltmeter (Figure 28) will display the generator’s output in VOLTS.

Figure 24. Engine Enclosure Doors

Figure 28. Voltmeter

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 31

Page 32

GENERATOR START-UP PROCEDURE (MANUAL)

5. If the voltage is not within the speciﬁed tolerance use the voltage adjustment control knob (Figure 29) to increase or decrease the desired voltage.

DECREASE

Figure 29. Voltage Adjust Control Knob

INCREASE

6. The ammeter (Figure 30) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 30. Ammeter (No Load)

Under normal operating conditions this speed is approximately 1800 RPM’s.

RPM X 100

TACH

HOURS

3010

0 0

Figure 33. Engine Tachometer Gauge

10. Place the main, G.F.C.I., and aux. circuit breakers (Figure 34) in the ON position.

7. The engine oil pressure gauge (Figure 31) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (241~448 kPa).

psi

bar

DATCON

100

OIL

PRESS

Figure 31. Oil Pressure Gauge

8. The coolant temperature gauge (Figure 32) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 180°~221°F (82°~105°C) (Green Zone).

150

DATCON

180

240

110

100

130

WATER

TEMP

Figure 32. Coolant Temperature Gauge

9. The tachometer gauge (Figure 33) will indicate the speed of the engine when the generator is operating.

Figure 34. Main, Aux. and GFCI

Circuit Breakers (ON)

11. Observe the generator’s ammeter (Figure 35) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 35. Ammeter (Load)

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

LIGHT TOWER OPERATION

NOTICE

For light tower operation, refer to the MLT20 Series Operation Manual (Part Number 49838).

PAGE 32 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 33

GENERATOR SHUT-DOWN PROCEDURES

STARTING (AUTO MODE)

DANGER

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

electrician must install an isolation (transfer) switch. Serious damage to

the building’s electrical system may occur

without this transfer switch.

NOTICE

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

NOTICE

When the MPEC control switch is placed in the AUTO mode, the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

1. Place the MPEC Control Switch (Figure 36) in the AUTO position.

AUTO

OFF/RESET

Figure 36. MPEC Control Switch (AUTO)

MANUAL

2. Continue operating the generator as outlined in the Manual Start-up procedure (start at step 2).

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

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

WARNING

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 33

Page 34

GENERATOR SHUT-DOWN PROCEDURES

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

WARNING

NEVER stop the engine suddenly except in an

emergency.

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 37) in the OFF position.

3. Place the MPEC Control Switch (Figure 38) to the OFF/RESET position.

AUTO

OFF/RESET

Figure 38. MPEC Control Switch (Off/Reset)

MANUAL

4. Verify that all the status LEDs on the MPEC display are OFF (not lit).

5. Remove all loads from the generator.

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

EMERGENCY SHUTDOWN PROCEDURE

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure 37) in the OFF position.

Figure 37. Main, Aux. and GFCI

Circuit Breakers (OFF

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

PAGE 34 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 35

MAINTENANCE

Engine

Generator

10 Hrs

DAILY

250 Hrs 500 Hrs

Table 11. Inspection/Maintenance

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

Replace Engine Oil and Filter *

Clean Air Filter X

Check Fuel Filter/Water Separator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*

Replace Air Filter Element *

Check all Hoses and Clamps *

Clean Inside of Fuel Tank X

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

*1 Replace engine oil and ﬁlter at 100 hours, ﬁrst time only.

*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

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

*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,

with no sags or dips that could collect moisture and/or oil.

1000

Hrs

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 11 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 39) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 39) is attached to the air cleaner. When the air cleaner element is clogged, air intake

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be

cleaned or reused. restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 35

Figure 39. Air Cleaner/Indicator

Page 36

MAINTENANCE

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

FUEL ADDITION

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

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 40) wash out any deposits or debris that have accumulated inside the fuel tank.

FUEL TANK INSPECTION

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

 Rubber Suspension — look for signs of wear or

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

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

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

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel ﬁlter cartridge with new one every 500

hours or so.

 Loosen the drain plug at the lower top of the fuel ﬁlter.

Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

 Vent any air

AIR REMOVAL

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

To restart after running out of fuel, turn the switch to the ON position for 15-30 seconds. Try again, if needed.

Figure 40. Fuel Tank Cleaning

PAGE 36 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 37

MAINTENANCE

CHECK OIL LEVEL

Check the crankcase oil level prior to each use, or when the fuel tank is ﬁlled. Insufﬁcient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 17 .

Replacing Oil Filter

 Remove the old oil ﬁlter.

 Apply a ﬁlm of oil to the gasket on the new oil ﬁlter.

 Install the new oil ﬁlter.

 After the oil cartridge has been replaced, the engine oil

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

FLUSHING OUT RADIATOR AND REPLACING COOLANT

 Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overﬂow tank and drain.

 Check hoses for softening and kinks. Check clamps for

signs of leakage.

 Tighten both cocks and replace the overﬂow tank.

 Replace with coolant as recommended by the engine

manufacturer.

 Close radiator cap tightly.

 Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

WARNING

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

RADIATOR CLEANING

The radiator (Figure 41) should be sprayed (cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling ﬁns or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the ﬁns and tube.

Figure 41. Radiator Cleaning

GENERATOR STORAGE

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

 Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

 Completely drain the oil from the crankcase and reﬁll if

necessary with fresh oil.

 Clean the entire generator, internal and external.

 Cover the generating set and store in a clean, dry place.

 Disconnect the battery.

 Make sure engine coolant is at proper level.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 37

Page 38

MAINTENANCE

JACKET WATER HEATER AND INTERNAL BATTERY CHARGER 120 VAC IN P U T RECEP TACLES (OPTIONAL)

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

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 42). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size.

NOTICE

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

Figure 42. Battery Charger and Jacket Water

Heater Power Connections

PAGE 38 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 39

TRAILER MAINTENANCE

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

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

The definitions below describe some of the major components of a typical trailer that would be used with generator.

1. Fuel Cell — Provides an adequate amount of fuel for

the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System — System employed in stopping

the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR — Gross Vehicle Weight Rating (GVWR) is

the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length — Measurement is from the ball hitch

to the rear bumper (reﬂector).

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 15 and Figure 45 for lug nut tightening and sequence.

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

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

5. Frame Width — Measurement is from fender to fender

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

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

15. Electrical — Electrical connectors (looms) are provided 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.

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 39

Page 40

TRAILER MAINTENANCE

BRAKES

Trailer brakes should be inspected the ﬁrst 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the ﬁrst 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Figure 43 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 12 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difﬁcult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

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

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 43) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 43. Hydraulic Brake Components

Actuator

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

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

Table 12. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Brake lining glazed? Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded? Correct weight.

Brake drums scored or grooved? Machine or replace.

Tire pressure correct? Inﬂate all tires equally.

Tires unmatched on the same axle? Match tires.

Brake components loose, bent or

broken?

Brake drums out-of-round? Replace.

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Brake lining thickness incorrect or

not adjusted correctly?

Enough brake ﬂuid or correct ﬂuid?

Replace components.

Install new shoes and

linings.

Replace rubber parts

ﬁll with dot 4 ﬂuid.

PAGE 40 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 41

TRAILER MAINTENANCE

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very impor tant 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

ALWAYS wear safet y glasses whe n

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

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

Suspension

The leaf suspension springs and associated components (Figure 44) 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 14.

Figure 44. Major Suspension Components

Tire inﬂation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot!. Check inﬂation pressure weekly during use to insure the maximum tire life and tread wear.

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

Table 13. Tire Wear Troubleshooting

Wear Pattern Cause Solution

Center Wear Over inﬂation.

Edge Wear Under inﬂation.

Side Wear

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

Loss of camber or overloading.

Wheel lockup and tire skidding.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating. Align wheels.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

Table 14. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-Bolt Min-30 Max-35

7/16" U-Bolt Min-45 Max-60

1/2" U-Bolt Min-45 Max-60

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.

Min-30 Max-50

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 41

Page 42

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 45). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as deﬁned by Table 15.

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

Table 15. Tire Torque Requirements

Wheel Size

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

TRAILER MAINTENANCE

Figure 45. Wheel Lug Nuts

Tightening Sequence

NOTICE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

PAGE 42 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 43

TRAILER WIRING DIAGRAM

Figure 46. Trailer/Towing Vehicle Wiring Diagram

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 43

Page 44

GENERATOR WIRING DIAGRAM

SYMBOL

Fg ExAr ExFg

AVR

CT 1,2

A V

CB1 CB2,3 CB4,5

CON1, 2 CON3,4

R1 Re1

J, K

COLOR CODE

WIRE COLOR

BLACK

BLUE

BROWN

GREEN

GRAY

VIOLET PINK

WIRE COLOR

RED

R W

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

DESIGNATION

MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR (RHEOSTAT) CURRENT TRANSFORMER CHANGE-OVER SWITCH,AMMETER AC.AMMETER AC.VOLTMETER FREQUENCY METER CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER RECEPTACLE RECEPTACLE RESISTOR RECTIFIER

RELAY UNIT

A J C

CN1

CN8

Notice:

1. With no designation use KIV1 : 1.25 mm lead of designated color.

E J

CN3

DKB

CN10

U V

R S T

CONNECTER ARRANGEMENT

(WIRING VIEW)

CN4

CN11

3 1 V U

CN5

324

C J A

BKD

CN12

CN7

2 3 4

J E

Figure 47. Generator Wiring Diagram

PAGE 44 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 45

ENGINE WIRING DIAGRAM

COLOR CODE

WIRE COLOR

BLACK

BLUE

BROWN

GREEN

GRAY

VIOLET

PINK

WIRE COLOR

RED

R W

WHITE

YELLOW

LIGHT BLUE

LIGHT GREEN

ORANGE

Figure 48. Engine Wiring Diagram

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 45

Page 46

TROUBLESHOOTING (GENERATOR)

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

Table 16. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check for approximately 17.3 ohms across J & K on CN1

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

PAGE 46 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 47

NOTES

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 47

Page 48

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

PART NO. Column

QTY. Column

— Item quantity can be indicated by a

A/R (As Required) is generally used for hoses or other

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁ ed in the “Remarks”

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed

same unique symbol will be included when this item is

— Used to list an effective serial

— Indicates that the part

part is NOT used on a speciﬁ c model or model number

available items. Examples include battery cables, shims,

— Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available

remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

Numbers Used

number, a blank entry, or A/R.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

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

2% WASHER, 1/4 IN. ..........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ..1 .....MQ-45T ONLY

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

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

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

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

NOTICE

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

parts that are sold in bulk and cut to length.

Column.

REMARKS Column

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

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

Speciﬁ c Model Number Use

is used only with the speciﬁ c model number or model number variant listed. It can also be used to show a

variant.

Indicated by:

Numbers Used — Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

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

PAGE 48 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of

and certain washers and nuts.

“Not Sold Separately”

for sale through Multiquip.

Page 49

DCA20SPXU2 WHISPERWATT GENERATOR WITH ISUZU BV-4LE2 DIESEL ENGINE

1 to 3 units

QTY. P/N DESCRIPTION

5............2944566410 .......... CARTRIDGE , OIL FILTER

1............M1310500803 ....... HOSE, RADIATOR UPPER

1............M1310500903 ....... HOSE, RADIATOR LOWER

1............0602011079 .......... RADIATOR CAP

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

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

1............0602123275 ......... UNIT, WATER TEMPERATURE

6............8980374810 .......... FILTER, FUEL CARTRIDGE

6............8944370220 .......... REPAIR KIT, FUEL PUMP

3............0602046321 .......... FILTER, AIR (ELEMENT)

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

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

1............LY2DUS12VDC .... RELAY

1............8972606490 .......... FAN BELT

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

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

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

SUGGESTED SPARE PARTS

NOTICE

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

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 49

Page 50

GENERATOR ASSY.

PAGE 50 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 51

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 B1110001402 ROTOR ASSY. ............................. 1 ...................INCLUDES ITEMS W/#

1-1# FIELD ASSY. ................................1 ...................NOT SOLD SEPARATELY

1-2# 7961025004 RECTIFIER 1 1-3# 0601822643 SURGE ABSORBER 1 1-4# 8001070003 FAN 1 1-5# 8351611004 COUPLING DISC 2 1-6# 8351612004 COUPLING HUB WASHER 1

1-7# B1112300003 BALANCING PLATE .................... 1 ...................WHEN ODERING, PURCHASE ITEM 1-10

1-8# 0010310025 HEX HEAD BOLT 4 1-9# 0042510000 WASHER, LOCK 4 1-10# 0601000209 BALANCING WEIGHT KIT 1 1-11# 0071906308 BEARING 1 2 0012308035 HEX HEAD BOLT 6 2A 0040080000 WASHER, LOCK 6 2B 0041208000 WASHER, FLAT 6 3 0070506803 BEARING 1 4 B1130001503 STATOR ASSY. 1 4-1 0845041904 GROMMET 1 5 B113700103 FIELD ASSY. EXCITER 1 6 0016008045 HEX HD CAP SCREW 3 7 0042508000 WASHER, LOCK 3 8 8351315003 END BRACKET 1 9 0017108035 HEX HEAD BOLT 6 10 8351312004 PACKING 1 11 8351331004 SUCTION COVER 1 12 0017106016 HEX HEAD BOLT 3 13 0010310030 HEX HEAD BOLT 6 13A 0040001000 WASHER, LOCK 6 13B 0041210000 WASHER, FLAT 6 14 B0155400204 FAN COVER 1 15 0010106030 HEX HEAD BOLT 1 16 0041206000 WASHER, FLAT 1 17 0600815000 NUT 1 18 M9312600004 RUBBER SUSPENSION 2 19 0207010000 HEX NUT 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 51

Page 52

CONTROL BOX ASSY.

35A

16A

37A

17A

16B

17B

PAGE 52 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 53

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1213001402 CONTROL BOX 1 1-1 0330000480 EDGING 1 1-2 0330000250 EDGING 1 2 0601870433 CIRCUIT BREAKER, 3P 90 AMPS 1 3 0021004075 MACHINE SCREW 4 4 0601842384 RESISTOR, 20W 50 OHM 1 5 0027104010 MACHINE SCREW 2 6 0601823240 RECTIFIER, DE45 3 7 0027104050 MACHINE SCREW 1 8 0601815759 TERMINAL BOARD, KT-20 6P 1 9 0027104020 MACHINE SCREW 2 10 0601820626 AUTO. VOLT. REGULATOR, NTA-4A-2S 1 11 0027105016 MACHINE SCREW 4 12 0601801123 CURRENT TRANSFORMER, 150/5A 2 13 0027106020 MACHINE SCREW 4 14 0601826031 RELAY, HE1 1 15 0027104010 MACHINE SCREW 2 16 0601824518 RELAY, DC 12V 2 16A 0601823143 BASE 2

16B PYCA1 CLIP ............................................................2 ................REPLACES P/N 0601824400

17 LY2DUS12VDC RELAY, DC 12V ...........................................1 ................REPLACES P/N 0601827656

17A PTF08A BASE ...........................................................1 ................REPLACES P/N 0601823109

17B PYCA1 CLIP ............................................................1 ................REPLACES P/N 0601824400

18 0027104020 MACHINE SCREW 6

19 8973259120 ENGINE CONTROLLER .............................1 ................REPLACES P/N 0602202523

20 0016906016 HEX HEAD BOLT 2

21 5825500290 RELAY .........................................................2 ................REPLACES P/N 0602201400

22 8944001061 GLOW RELAY .............................................1 ................REPLACES P/N 0602202502

23 0027105016 MACHINE SCREW 4 24 M1213500803 CONTROL BOX COVER 1 25 0016906016 HEX HEAD BOLT 5 26 0016906015 HEX HEAD BOLT 9

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 53

Page 54

CONTROL BOX ASSY. (CONTINUED)

35A

16A

37A

17A

16B

17B

PAGE 54 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 55

CONTROL BOX ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 27 M1223001003 CONTROL PANEL 1 28 0601807641 FREQUENCY METER, 45~65Hz 240V 1 29 0601806844 AC AMMETER, 0~150A 1 30 0601801040 AMMETER, CHANGE-OVER SWITCH 1 31 0601800271 AC VOLTMETER, 0~300V 1 32 0601840073 RHEOSTAT (VR), 2W 1K OHM 1 33 0601840121 KNOB 1 34 0602202545 CONTROLLER, ECU-9988N 1 35 0027104040 MACHINE SCREW 2 35A 0207004000 HEX NUT 2 36 0601831340 SWITCH, MPEC 1 37 0602103092 ALARM LAMP, PL-05 1 37A 0601810245 BULB, DC 18V 1 38 0602120095 TACHOMETER 1 39 0602122093 OIL PRESSURE GAUGE 1 40 0602123090 WATER TEMP. GAUGE 1 41 0602121080 CHARGING AMMETER 1 42 0602125090 FUEL GAUGE 1 43 0601810141 PANEL LIGHT 1 44 0601831330 SWITCH, PANEL LIGHT 1 45 M1223100104 STOPPER 1 46 0027105010 MACHINE SCREW 2 47 0027105010 MACHINE SCREW 4 48 M9220100004 SET SCREW 2 49 0080200007 SNAP RING 2 50 M1246704404 WIRE HARNESS, GENERATOR 1 51 M1357201902 WIRE HARNESS, ENGINE 1

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 55

Page 56

ENGINE AND RADIATOR ASSY.

9-2

9-3

22A

17A

PAGE 56 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 57

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1923200104 ENGINE, ISUZU 4LE2 1 1A 8972606490 FAN BELT 1 1-1 2944566410 OIL FILTER CARTRIDGE 1 2 M1303200304 ENGINE FOOT 1 3 M1305200204 ENGINE FOOT 1 4 0010310025 HEX HEAD BOLT 8 5 0040010000 WASHER, LOCK 8 6 0041210000 WASHER, FLAT 8 7 0605000066 RUBBER SUSPENSION 2 8 0207010000 HEX NUT 2 9 M1923200094 RADIATOR 1 9-1 0602011079 RADIATOR CAP 1 9-2 M9200100904 PLUG 1 9-3 0150000016 O-RING 1 10 M9312200104 RUBBER MOUNT 2 11 0016908040 HEX HEAD BOLT 2 12 0207008000 HEX NUT 2 13 M1310500803 RADIATOR HOSE, UPPER 1 14 M1310500903 RADIATOR HOSE, LOWER 1 15 0605515069 HOSE BAND 4 16 M1310200003 FAN SHROUD 1 17 M1310200103 FAN SHROUD 1 17A M1493105004 ACCOUSTIC SHEET 1 18 0016908020 HEX HEAD BOLT 8 19 M1310300703 FAN GUARD 1 20 M1310300804 FAN GUARD 1 21 0016908020 HEX HEAD BOLT 8 22 0602046531 AIR CLEANER 1 22A 0602046321 AIR CLEANER ELEMENT 1 23 0602040690 AIR CLEANER INDICATOR 1 24 0602040552 AIR CLEANER BRACKET 1 25 0016908030 HEX HEAD BOLT 2 26 M1373100303 AIR CLEANER HOSE 1 27 M1373100503 AIR CLEANER HOSE 1 28 0605515139 HOSE BAND 3 29 0602022560 ADAPTER 1 30 M1320300304 PACKING 1

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 57

Page 58

ENGINE AND RADIATOR ASSY. (CONTINUED)

9-2

9-3

22A

17A

PAGE 58 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 59

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 31 0602022561 90 DEGREE ELBOW 1 32 0603306590 CONNECTOR 1 33 0603300285 LOCKNUT 1 34 0605511395 VALVE 1 35 0603306395 HOSE JOINT 1 36 0602021070 CAP 1 37 0269200280 DRAIN HOSE 1 38 M9602000003 DRAIN JOINT 1 39 M9200200004 PLUG 1 40 0150000018 O-RING 1 41 0016906020 HEX HEAD BOLT 2 42 0199900600 DRAIN HOSE 1 43 0199900500 DRAIN HOSE 1 44 0605515106 HOSE BAND 4 45 M9300100003 RESERVE TANK 1 46 M9300100003 RESERVE TANK CAP 1 47 0199100215 HOSE 1 48 M1317100004 RESERVE TANK BRACKET 1 49 0199100350 HOSE 1 50 0193600850 HOSE 1 51 0605515106 HOSE BAND 2 52 0602120481 TACHOMETER PICK UP 1 53 0602122272 OIL PRESSURE UNIT 1 54 M9200100004 ADAPTER 1 55 0602123275 WATER TEMPERATURE UNIT 1 56 M1353800004 CLAMPER ROD 1 57 0016908020 HEX HEAD BOLT 2 58 M1357300104 CLAMPER ROD 1 59 0016910020 HEX HEAD BOLT 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 59

Page 60

OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART

NUMBER WHEN ORDERING ANY PAINTED PANEL TO

INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK

2-WHITE 6-CATERPILLAR YELLOW

3-SPECTRUM GREY 7-CATO GOLD

4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 60 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 61

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1230700203 TERMINAL PANEL 1 2 M9220000204 OUTPUT TERMINAL BOLT 4 3 M9220000104 TIE BOLT 4 4 0039308000 HEX BRASS NUT 8 5 0040008000 WASHER, LOCK 12 6 0041408000 WASHER, FLAT 16 7 0016906025 HEX HEAD BOLT 4 8 M1236101503 TERMINAL COVER 1 9 M1236100404 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX HEAD NUT 4 11B 0041203000 WASHER, FLAT 4 12 0027103010 MACHINE SCREW 4 12A 0030003000 HEX HEAD NUT 4 13 M9220100804 SET SCREW 2 13A 0040006000 WASHER, LOCK 2 13B 0041206000 WASHER, FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906016 HEX HEAD BOLT 4 15 M1236400004 CABLE OUTLET COVER 1 16 M1236300004 CABLE OUTLET COVER SUPPORTER 1 17 0016906020 HEX HEAD BOLT 6 18 0601815194 TERMINAL 1 19 0027104016 MACHINE SCREW 2 20 0601870441 CIRCUIT BREAKER, 2P 50A 2 21 0601870440 CIRCUIT BREAKER, 1P 20A 2 22 M1260700404 BREAKER FITTING COVER 1 22-1 0222100080 RUBBER CUSHION 2 23 0016906020 HEX HEAD BOLT 2 24 0601814013 RECEPTACLE, 125V 20A (GF-20LA) 2 25 0601812538 RECEPTACLE, 250V 50A (CS6369) 2 26 0027104016 MACHINE SCREW 8 26A 0207004000 HEX NUT 8 27 M1236400104 COVER 1 28 0016906016 HEX HEAD BOLT 4 29 M1236100503 TERMINAL COVER 1 30 0010112045 HEX HEAD BOLT 2 31 0041212000 WASHER, FLAT 2 32 M9310200004 RUBBER STAY 2 33 0030012000 HEX NUT 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 61

Page 62

BATTERY ASSY.

PAGE 62 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 63

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 0602220185 BATTERY 1 2 B9310500014 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 0040006000 WASHER, LOCK 2 6 M1348400204 BATTERY CABLE 1 7 M2346400104 BATTERY CABLE 1 8 0016910020 HEX HEAD BOLT 1 8A 0040510000 TOOTHED WASHER 3

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 63

Page 64

MUFFLER ASSY.

PAGE 64 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 65

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1330100803 MUFFLER 1 2 0016908020 HEX HEAD BOLT 4 3 M1333002803 EXHAUST PIPE 1 4 0602320100 GASKET 1 5 M1333200014 GASKET 1 6 0207008000 HEX NUT 4 7 0016908035 HEX HEAD BOLT 4 8 M1330400804 COVER 2 9 0016906016 HEX HEAD BOLT 4 10 49685 TUBE, EXHAUST EXTENSION 1 11 12597 CLAMP, 2" MUFFLER SADDLE 1

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 65

Page 66

14A

FUEL FILTER ASSY.

17A

PAGE 66 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 67

FUEL FILTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

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

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

15 M1366700104 FUEL FILTER BRACKET 1 16 0016908020 HEX HEAD BOLT 6

17 8970398340 FUEL PUMP ................................................1 ................REPLACES P/N 0602023177

17A 8944370220 FUEL FILTER (FUEL PUMP) ......................1 ................REPLACES P/N 0602042425

18 0016906025 HEX HEAD BOLT 2 19 0191200900 SUCTION HOSE 1 20 0191200300 SUCTION HOSE 1 21 0191200650 SUCTION HOSE 1 22 0191201100 RETURN HOSE 1 23 0605515108 HOSE BAND 2 24 0605515198 HOSE BAND 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 67

Page 68

ENCLOSURE ASSY.

PAGE 68 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 69

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M1413003302 BASE 1 2 M1413400004 UNDER COVER 1 3 0016908020 HEX HEAD BOLT 2 4 M1423002302 FRONT FRAME 1 4A M1493104903 ACOUSTIC SHEET 1 5 0016908020 HEX HEAD BOLT 4 6 49727 PANEL,UPPER BALLAST COVER 1

6A 60131 WEATHERSTRIP .......................................12 ...............1 PC = 1 FT.

7 49726 PANEL, LOWER BALLAST COVER 1 7A 0019208020 HEX HEAD BOLT 11 8 M1433000203 CENTER FRAME 1 9 M1433000303 CENTER FRAME 1 10 0010114030 HEX HEAD BOLT 8 10A 0040014000 WASHER, LOCK 8 10B 0041214000 WASHER, FLAT 8 11 M1443001902 REAR FRAME 1 12 0016908020 HEX HEAD BOLT 4 13 M1443301803 REAR COVER 1 14 M1443301703 REAR COVER DUCT 1 14A M1493303604 ACOUSTIC SHEET 1 15 0207006000 HEX NUT 7 16 0019208020 HEX HEAD BOLT 7 17 M1443200613 REAR DOOR 1 18 M1443600114 WINDOW PLATE 1 19 0037906000 U-NUT 8 19A 0041206000 WASHER, FLAT 8 20 M9113000002 DOOR HANDLE ASSY. 1 21 0021806016 MACHINE SCREW 4 21A 0030006000 HEX HEAD NUT 4 22 M9110100204 HINGE 2 23 M9116100004 WASHER 2 24 0019208020 HEX HEAD BOLT 3 25 M9310000004 BLIND PLUG 2 26 M1463002202 ROOF PANEL 1 26A M1493502903 ACOUSTIC SHEET 1 27 0019208020 HEX HEAD BOLT 18 28 M3310600004 ROOF COVER 1 29 0019208020 HEX HEAD BOLT 1 30 M1453201202 SPLASHER PANEL 1 31 0019108055 HEX HEAD BOLT 2 31A 0042308000 WASHER, LOCK 2 31B 0042408000 WASHER, FLAT 2 32 0016908020 HEX HEAD BOLT 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 69

Page 70

ENCLOSURE ASSY. (CONTINUED)

PAGE 70 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 71

ENCLOSURE ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

33 M1453003803 SIDE DOOR 1 33A M1493405604 ACOUSTIC SHEET 1 34 M1453003903 SIDE DOOR 1 34A M1493405704 ACOUSTIC SHEET 1 35 M1453004003 SIDE DOOR 1 35A M1493405804 ACOUSTIC SHEET 1 36 M1453004703 SIDE DOOR 1 36A M1493409404 ACOUSTIC SHEET 1 37 M1453301403 DUCT 1 38 0207006000 HEX NUT 8 39 B9114000002 DOOR HANDLE ASSY. 3 40 0021806016 MACHINE SCREW 12 40A 0030006000 HEX HEAD NUT 12 41 M9110100204 HINGE 4 42 M9110100304 HINGE 4 43 M9116100004 WASHER 8 44 0019208020 HEX HEAD BOLT 9 45 0601850097 DOOR STOPPER 8 46 0027208025 MACHINE SCREW 8 47 M9310000004 BLIND PLUG 8 48 0600500090 EMBLEM 1 49 0025106016 MACHINE SCREW 2 50 0016910020 HEX HEAD BOLT 1 50A 0040510000 TOOTHED WASHER 1 51 0016908020 HEX HEAD BOLT 1 51A 0040508000 TOOTHED WASHER 1 52 0016906020 HEX HEAD BOLT 1 52A 0040506000 TOOTHED WASHER 1 53 0600800321 MANUAL HOLDER 1 54 M1483600804 MANUAL HOLDER CLAMP 1 55 0016906016 HEX HEAD BOLT 4

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 71

Page 72

RUBBER SEALS ASSY.

PAGE 72 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 73

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901150 RUBBER SEAL 2 2 0228900695 RUBBER SEAL 3 3 0228900755 RUBBER SEAL 1 4 M1490300004 RUBBER SEAL 1 5 0228800325 RUBBER SEAL 1 6 0229400430 RUBBER SEAL 1 7 0228900540 RUBBER SEAL 1 8 0228900550 RUBBER SEAL 1 9 0229200595 RUBBER SEAL 1 10 0228900610 RUBBER SEAL 1 11 0229200750 RUBBER SEAL 2 12 0229200740 RUBBER SEAL 1 13 0228800670 RUBBER SEAL 2 14 0228800525 RUBBER SEAL 1 15 0228800565 RUBBER SEAL 1 16 0228100458 RUBBER SEAL 1 17 0228100171 RUBBER SEAL 1 18 0228100351 RUBBER SEAL 1 19 0228100285 RUBBER SEAL 1 20 0228100153 RUBBER SEAL 1 21 0228100180 RUBBER SEAL 1

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 73

Page 74

NAMEPLATE AND DECALS ASSY.

PAGE 74 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 75

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M1550001803 DECAL; AUXILIARY OUTPUT ..................................1 ........... M15000180

2 M1550001904 DECAL; CAUTION .....................................................1 ........... M15000190

3 M1550003902 DECAL; GENERATOR CONTROL ............................1 ........... M15000390

4 M1550004002 DECAL; ENGINE OPERATING .................................1 ........... M15000400

5 M1550004103 DECAL; OPERATING PROCEDURES ......................1 ........... M15000410

6 M9500000004 DECAL; OIL DRAIN PLUG ........................................1 ........... M90000000

7 M9500100004 DECAL; WATER ........................................................1 ........... M90010000

8 M9500300004 DECAL; - ...................................................................1 ........... M90030000

9 M9500300104 DECAL; + ...................................................................1 ........... M90030010

10 M9500500104 DECAL; FUEL DRAIN PLUG ....................................1 ........... M90050010

11 M9500500304 DECAL; DIESEL FUEL ..............................................1 ........... M90050030

12 M9503000004 DECAL; WARNING ....................................................2 ........... M90300000

13 M9503000103 DECAL; WATER - OIL CHECK ..................................1 ........... M90300010

14 M9503100004 DECAL; WARNING ....................................................1 ........... M90310000

15 M9503200004 DECAL; WARNING ....................................................1 ........... M90320000

16 M9503200104 DECAL; DANGER .....................................................1 ........... M90320010

17 M9510000104 DECAL; DOCUMENT BOX LOCATED ......................1 ........... M91000010

18 M9510100004 DECAL; CAUTION .....................................................2 ........... M91010000

19 M9510200002 DECAL; MQ ...............................................................1 ........... M91020000

20 M9520000004 DECAL; GROUND .....................................................1 ........... M92000000

21 M9520000104 DECAL; AMMETER CHANGE-OVER SW ................1 ........... M92000010

22 M9520000504 DECAL; START CONTACT ........................................1 ........... M92000050

23 M9520100004 DECAL; WARNING ....................................................2 ........... M92010000

24 M9520100304 DECAL; SAFETY INSTRUCTIONS ...........................1 ........... M92010030

25 M9520100404 DECAL; DANGER .....................................................1 ........... M92010040

26 M9520100503 DECAL; WARNING ....................................................1 ........... M92010050

27 M9520100603 DECAL; CAUTION .....................................................1 ........... M92010060

28 M9521000004 DECAL; TERMINAL 1 29 M1560102604 STRIPE; WHISPERWATT 1 30 M1560102604 STRIPE; 20 2 31 M1560101604 DECAL; MQ POWER 2 32 M1560101704 STRIPE 2 33 M1560101804 STRIPE 2

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 75

Page 76

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

5. Par ts must be in new and resalable

Multiquip reserves the right to quote and

who use our products as integral parts of their

LIMITATIONS OF SELLER’S LIABILITY

liable for loss of proﬁ t or good will or for any

connection with the sale of its products. Apart

statutory, which extend beyond the description

Terms of payment for parts are net 30 days.

FREIGHT POLICY

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

MINIMUM ORDER

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

RETURNED GOODS POLICY

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

1. A Retur n ed Ma ter ial Auth orizati on must be approved by Multiquip prior to shipment.

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

a. The parts numbers and descriptions

b. The list must be typed or computer

c. The list must state the reason (s)

d. The list must reference the sales

e. The list must include the name

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

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

must match the current parts price list.

generated.

for the return.

order ( s ) o r i n v o i c e (s ) u n d e r which the items were originally purchased.

and phone number of the person requesting the RMA.

co ndi tio n, in the ori gin al Mult iqu ip package (if any), and with Multiquip part numbers clearly marked.

6. The following items are not returnable:

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

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

b. Any parts with a limited shelf life

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

c. Any line item with an extended

dea l e r ne t pr i c e of le s s th a n $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants.

g. Decals and paper products.

h. Items purchased in kits.

7. The sender will be notiﬁ ed of any material received that is not acceptable.

8. Suc h mater ial wil l be held for five working days from notiﬁ cation, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

9. Credit on returned parts will be issued at dealer net price at time of the original pur c h a s e, le s s a 15 % rest o c k i ng charge.

10. In cases where an item is accepted, for which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

11. Credit issued will be applied to future purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a speciﬁ c date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

sell direct to Government agencies, and to Original Equipment Manufacturer accounts

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be

other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warra nti es, expre ss or impli ed, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor author izes any person to assum e for it any other obligation or liability whatever in

from such writ ten statement of warranty, there are no warranties, express, implied or

of the products on the face hereof.

Effective: February 22, 2006

PAGE 76 — DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13)

Page 77

NOTES

DCA20SPXU2 (WITH MLT20 SERIES) • OPERATION AND PARTS MANUAL — REV. #0 (01/18/13) — PAGE 77

Page 78

OPERATION AND PARTS MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc of their respective owners and used with permission.

This manual

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

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

United StateS

Multiquip Corporate Ofﬁce MQ Parts Department

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

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

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

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

Fax: 310-537-4259 800-421-1244

800-427-1244 310-537-3700

310-537-3700

Fax: 800-672-7877 Fax: 310-637-3284

Fax: 310-943-2249

mexico United Kingdom

MQ Cipsa Multiquip (UK) Limited Head Ofﬁce

Carr. Fed. Mexico-Puebla KM 126.5 Momoxpan, Cholula, Puebla 72760 Mexico Contact: pmastretta@cipsa.com.mx

Tel: (52) 222-225-9900 Fax: (52) 222-285-0420

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

Canada

Multiquip

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

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

Tel: 0161 339 2223 Fax: 0161 339 3226

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

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

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PN 49840

Multiquip DCA20SPXU2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual