PARTS AND OPERATION MANUAL OPERATION MANUAL WHISPERWATTTM SERIES MODEL DCA-15SPXU4 60 Hz GENERATOR Revision #0 (03/31/11) THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA-15SPXU4— OPERATION MANUAL — REV.
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TABLE OF CONTENTS MQ POWER DCA-15SPXU4 WHISPER WATTTM GENERATOR WHISPERW California Proposition 65 Warning ..................................... 2 Table Of Contents ............................................................. 4 Parts Ordering Procedures ............................................... 5 Specifications ................................................................... 6 Dimensions (Top, Side, Front) .......................................... 7 Safety Message Alert Symbols ..................
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DCA-15SPXU4 — SPECIFICATIONS Table 1. Generator Specifications Model DCA-15SPXU4 Type Revolving field, self ventilated, open protected type synchronous generator Phase Single Phase 3-Wire Standby Output 16.5 KW Prime Output 15 KW Voltage 240V/120 Frequency 60 Hz Speed 1800 rpm Power Factor 1.0 Aux. AC Power (GFCI) 2.4 KW @120 VAC Single Phase, 60 Hz Aux. AC Power (L5-30R) 3.6 KW@120 VAC Single Phase, 60 Hz Aux. AC Power (L6-30R ) 7.2 KW@240 VAC Single Phase, 60 Hz Aux.
DCA-15SPXU4 — DIMENSIONS (TOP, SIDE AND FRONT) A TOP VIEW B C Figure 1. Dimensions 15 MQPOWER WHISPERWATT SIDE VIEW D FRONT VIEW TABLE 3. DIMENSIONS E U Reference Letter Dimension in. (mm.) A 21.65 (550) B 20.07 (510) C 21.85 (555) D 61.02 (1,550) E 35.43 (900) F 25.60 (650) N V Denyo F 1 DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS! Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others. NOTE This Owner's Manual has been developed to provide complete instructions for the safe and efficient operation of the MQ Power Model DCA-15SPXU4 Whisperwatt™ Generator.
DCA-15SPXU4 — SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury. CAUTION - ACCIDENTAL STARTING ALWAYS place the engine ON/OFF switch (MPEC) in the OFF/RESET position when the generator is not in use. CAUTION - OVER-SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings.
DCA-15SPXU4 — RULES FOR SAFE OPERATION DANGER - READ THIS MANUAL! Failure to follow instructions in this manual may lead to serious injury or even DEATH! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only. The following safety guidelines should always be used when operating the DCA-15SPXU4 Whisperwatt™ AC Generator. ■ NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment.
DCA-15SPXU4 — RULES FOR SAFE OPERATION ■ ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generators. ■ NEVER leave the generator unattended, turn off engine when unattended. ■ Unauthorized equipment modifications will void all warranties. ■ ALWAYS ensure generator is on level ground before use. ■ DO NOT place hands or fingers inside generators engine compartment when engine is running.
DCA-15SPXU4 — RULES FOR SAFE OPERATION WARNING - BURN HAZARDS To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.
DCA-15SPXU4 — RULES FOR SAFE OPERATION Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a posion you cannot see or smell 20A 2900 120 V OFF GA-2.9R 120V 20A 2900 120V ON OFF AC CIRCUIT BREAKER 20A 2900 120 V GA-2.9R 22A NEVER grab or touch a live power cord with wet hands, the possibility exist of electrical shock, electrocution, and even death! DANGER 120 V ON GA-2.
DCA-15SPXU4 — RULES FOR SAFE OPERATION If your generator is trailer mounted, please read the towing and safety requirements listed below. Towing and Transporting Safety To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.
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DCA-15SPXU4 — INSTALLATION Figure 2. Typical Generator Grounding Application PAGE 16 — DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — INSTALLATION Outdoor Installation Generator Grounding 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.
DCA-15SPXU4 — GENERAL INFORMATION DCA-15SPXU4 Whisperwatt™ Series Familiarization Generator This MQ Power generator is a 15 kW generator (Figure 3) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.
DCA-15SPXU4 — MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. Figure 3. Major Components DESCRIPTION 1 Air Filter Assembly 2 Muffler Assembly 3 Engine and Radiator Assembly 4 Generator Assembly 5 Battery Assembly 6 Fuel Tank Assembly 7 Generator Control Panel Assembly 8 Output Receptacle Assembly 9 Output Terminal Assembly DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — GENERATOR CONTROL PANEL 4 1 2 3 WATER TEMP. HZ 19 18 17 16 A OIL PRESS. BATT. LOW LEVEL PREHEAT LAMP V INCREASE DECREASE 5 6 7 8 U N 9 V 15 14 13 12 11 10 Figure 4. Generator Control Panel PAGE 20 — DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — GENERATOR CONTROL PANEL The definitions below describe the controls and functions of the Generator Control Panel (Figure 4). C. Preheat – Use this position before starting during cold weather operating conditions. Observe the Preheat Lamp for indication of the proper time for starting the engine. 1. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz. 2.
DCA-15SPXU4 — OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel The Output Terminal Panel (Figure 5) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal lugs.
DCA-15SPXU4 — OUTPUT TERMINAL PANEL FAMILIARIZATION L5-30R Twist Lock 120 VAC Receptacle 120 VAC GFCI Receptacle This120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacle There is one L5-30R, 120 VAC 30 amp auxilliary twist-lock can be used anytime the generator is in operation. Remember receptacle (Figure 8) provided on the output terminal panel. the load output (current) of the GFCI receptacle is dependent on the load requirements of the U, N, and V output terminal lugs.
DCA-15SPXU4 — OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the Ouput 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, 70A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine. Figure 11.
DCA-15SPXU4 — LOAD APPLICATION/MAXIMUM AMPERAGE 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.
DCA-15SPXU4 — GAUGE READING/ TERMINAL PANEL CONNECTIONS UNV Terminal Output Voltages 240/120V output voltages can be obtained using the Output Terminal Lugs. Use the voltage regulator (VR) to either increase or decrease the selected voltage. Ammeter Gauge. The ammeter gauge (Figure 15) on the generator control panel has been provided to help observe how much current (amps) is being supplied to the load from the output terminal lugs, GFCI receptacle or any auxulliary receptacles if installed.
DCA-15SPXU4 — SETUP Fuel Check Circuit Breakers To protect the generator from an overload, a 3-pole, 70 amp, main circuit breaker is provided to protect the U,N,and V OUTPUT TERMINALs from overload.. In addition a two-pole, 50 amp CS6369 circuit breaker is provided to protect the CS6369 receptacle from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine. DANGER - EXPLOSION/FIRE HAZARDS Fuel spillage on a hot engine can cause a fire or explosion.
DCA-15SPXU4 — SETUP Refueling Procedure: NOTE WARNING - RESPIRATORY HAZARDS Diesel fuel and its vapors are dangerous to your health and the surrounding 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 19). 3. If generator is equipped with an environmental fuel tank, reference Figures 21 and 22.
DCA-15SPXU4 — SETUP Coolant (Antifreeze/Summer Coolant/Water) KUBOTA 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 KUBOTA Engine Owner's Manual for further details. Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air.
DCA-15SPXU4 — SETUP Battery When connecting battery do the following: This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery terminals when the ignition switch is in the ON position Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not 2. Place a small amount of battery terminal treatment properly maintained. Add only distilled water when compound around both battery terminals.
DCA-15SPXU4 — GENERATOR START-UP PROCEDURE Before Starting CAUTION - LETHAL EXHAUST HAZARD The engine's exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. Start-up Procedure 1. Set the Speed Control Switch to the START/IDLE position (Figure 27). WARNING - STARTING THE GENERATOR NEVER! manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position. Figure 27.
DCA-15SPXU4 — GENERATOR START-UP PROCEDURE 5. Set the Speed Control Switch to the RUN position (Figure 30). 8. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 34). Figure 30. Speed Control Switch (RUN) 6. The ammeter (Figure 31) 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 34. Main, GFCI, and Aux. Circuit Breakers (ON) 9.
DCA-15SPXU4 — GENERATOR SHUT-DOWN PROCEDURES WARNING - SHUTTING DOWN THE GENERATOR NEVER stop the engine suddenly except in an emergency. Normal Shutdown Procedure To shutdown the generator use the following procedure: Emergency Shutdown Procedure 1. Turn the ignition key counter-clockwise to the STOP position. When the engine has stopped, remove key. Place key in a safe place where it will not be lost. 2. Place both the main, GFCI, and aux. circuit breakers as shown in Figure 25 to the OFF position. 1.
DCA-15SPXU4 — MAINTENANCE 10 Hrs DAILY TABLE 11.
DCA-15SPXU4 — MAINTENANCE Flushing Out Radiator and Replacing Coolant Air Removal If air enters the fuel injection system of a diesel engine, Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system radiator cap while draining. Remove the overflow tank according to the following procedure. See the KUBOTA and drain.
DCA-15SPXU4 — MAINTENANCE Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL) This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel. The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger. These receptacles will ONLY function when commercial power has been supplied to them (Figure 36).
DCA-15SPXU4 — 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 37 displays the major hydraulic surge brake components that will require inspection and maintenance.
DCA-15SPXU4 — TRAILER MAINTENANCE Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched. CAUTION - EYESIGHT HAZARD Suspension The leaf suspension springs and associated components (Figure 38) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners.
DCA-15SPXU4 — TRAILER MAINTENANCE Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1. Start all wheel lug nuts by hand. 2. Torque all lug nuts in sequence (see Figure 39). 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.
DCA-15SPXU4 — GENERATOR WIRING DIAGRAM Figure 40. Generator Wiring Diagram PAGE 40 — DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — ENGINE WIRING DIAGRAM Figure 41. Engine Wiring Diagram 1 DCA-15SPXU4— OPERATION MANUAL — REV.
DCA-15SPXU4 — TROUBLESHOOTING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 16 shown below for diagnosis of the engine. If the problem cannot be remedied, consult our company's business office or service plant. TABLE 16. ENGINE TROUBLESHOOTING SYMPTOM Engine does not star t. POSSIBLE PROBLEM SOLUTION No fuel? Replenish fuel. Air in the fuel system? Bleed system.
DCA-15SPXU4 — TROUBLESHOOTING (ENGINE) TABLE 16. ENGINE TROUBLESHOOTING (CONTINUED) SYMPTOM POSSIBLE PROBLEM Engine revolution is not smooth. Either white or blue exhaust gas is observed. Either black or dark gray exhaust gas is observed. Deficient output. SOLUTION Fuel filter clogged or dir ty? Clean or change. Air cleaner clogged? Clean or change. Fuel leak due to loose injection pipe retaining nut? Tighten nut. Injection pump malfunctioning? Repair or replace.
DCA-15SPXU4 — TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company's business office or service plant. TABLE 17.
DCA-10SPX4 — TROUBLESHOOTING (PRE-HEAT LAMP CODES) When the Emergency/Malfunction Diagnosis Function has been activated, it stops the engine and flashes the pre-heat lamp to indicate the cause of the malfunction with its flashing patterns. The flashing patterns and countermeasures are shown below. The patterns consist of combinations of one or more long flashes and one or more short flashes. TABLE 18.
PARTS AND OPERATION MANUAL OPERATION MANUAL HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com MQ Parts Department Tel.