MQ Power WHISPERWATT Series Operation Manual
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MQ Power WHISPERWATT Series Operation Manual

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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA20SPXU4F
60 Hz GENERATOR
(ISUZU 4LE2T DIESEL ENGINE)
INSTRUCTION MANUAL NO. M1844300324C
Revision #6 (09/07/22)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Summary of Contents for MQ Power WHISPERWATT Series

  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA20SPXU4F 60 Hz GENERATOR (ISUZU 4LE2T DIESEL ENGINE) INSTRUCTION MANUAL NO. M1844300324C Revision #6 (09/07/22) To find the latest revision of this publication or associated parts manual, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA20SPXU4F 60 Hz Generator Proposition 65 Warning ........... 2 Table of Contents ............. 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............14–15 General Information ..........16 Major Components ..........17 Engine/Generator Control Panel......

  • Page 4: Safety Decals

    SAFETY DECALS Safety decals are attached to the generator as shown in NOTICE Figure 1. Keep these safety decals clean at all times. When For safety decal part numbers, refer to the associated the safety decals become worn or damaged, contact your parts manual.

  • Page 5: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 6 „ NEVER use accessories or attachments that are not being used. The generator should be stored in a clean, dry location out of the reach of children and unauthorized recommended by MQ Power for this generator. Damage to the generator and/or injury to the user may result. personnel.
  • Page 7 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 8 „ The trailer should be adjusted to a level position at all times when towing. „ Refer to the MQ Power trailer manual for additional safety information. „ Raise and lock the trailer wheel stand in the upright position when towing.
  • Page 9 SAFETY INFORMATION ELECTRICAL SAFETY „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. „ NEVER touch the output terminals NOTICE during operation. Contact with the „...
  • Page 10 SAFETY INFORMATION EMISSIONS INFORMATION „ If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty NOTICE of water and contact the nearest doctor or hospital to seek medical attention. The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CAUTION (CO), hydrocarbons (HC), and nitrogen oxides (NOx)

  • Page 11: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA20SPXU4F Type Revolving field, self-ventilated, protected type synchronous generator Armature Connection Series Phase Standby Output 22.0 kW (27.5 kVA) Prime Output 20 kW (25 kVA) Voltage (L-L/L-N) 240/120 Power Factor Frequency 60 Hz Speed 1,800 rpm Aux.

  • Page 12: Dimensions

    DIMENSIONS 3,240 lb. (1,470 kg) Figure 2. Dimensions Table 3. Dimensions Reference Reference Dimension in. (mm) Dimension in. (mm) Letter Letter 22.91 (582) 22.36 (568) 21.73 (552) 71.65 (1,820) 22.36 (568) 49.61 (1,260) 26.38 (670) 31.10 (790) PAGE 12 — DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22)
  • Page 13 NOTES DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22) — PAGE 13...

  • Page 14: Installation

    GENERATOR GROUND LUG GROUND ROD GROUND CABLE REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22)
  • Page 15 INSTALLATION OUTDOOR INSTALLATION MOUNTING Install the generator in an area that is free of debris, The generator must be mounted on a solid foundation bystanders, and overhead obstructions. Make sure the (such as concrete) and set firmly on the foundation to generator is on secure, level ground so that it cannot slide isolate vibration of the generator when it is running.

  • Page 16: General Information

    „ “Control Box” (located behind Control Panel) Reference Table 2 for engine specifications. • Automatic Voltage Regulator In keeping with MQ Power’s policy of constantly improving • Current Transformer its products, the specifications quoted herein are subject • Starter Relay to change without prior notice.

  • Page 17: Major Components

    MAJOR COMPONENTS 9 10 Table 4. Generator Major Components ITEM NO. DESCRIPTION Muffler Assembly Output Terminal Panel Assembly Emergency Stop Switch Assembly S/N 8720596 and Above Generator Assembly Engine Assembly Coolant Drain Assembly Fuel Tank Assembly Oil Drain Assembly Main Circuit Breaker Assembly Generator Control Panel Assembly Gauge Unit Assembly Battery Assembly...

  • Page 18: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL Integrated G augeControl LowOilPressure HighTemp OverCrank OverSpeed n/min n/min Engine Integrated G augeControl Started Fuel LowOilPressure HighTemp OverCrank OverSpeed n/min n/min Engine Started Fuel Figure 5. Engine/Generator Control Panel The definitions below describe the controls and functions F.
  • Page 19 ENGINE/GENERATOR CONTROL PANEL 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.

  • Page 20: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 6) shown below is The “Output Terminal Panel” (Figure 6) is provided with located on the right-hand side (left from control panel) of the following: the generator.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles NOTICE It is recommended that the GFCI receptacles be tested when the generator is initially uncrated. The receptacles should then be tested daily at startup. There are two 120 VAC, 20-amp GFCI (duplex NEMA 5-20R) receptacles provided on the output terminal panel.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator (Figure 10) by the output terminal lugs, convenience receptacles,or optional cam-loks. 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, 90-amp main circuit breaker is provided.

  • Page 23: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD NOTICE Always be sure to check the nameplate on the generator Motors and motor-driven equipment draw much greater and equipment to ensure the wattage, amperage, frequency, current for starting than during operation. and voltage requirements are satisfactorily supplied by the An inadequately sized connecting cable which cannot generator for operating the equipment.

  • Page 24: Ac Ammeter Gauge Reading

    AC AMMETER GAUGE READING HOW TO READ THE AC AMMETER GAUGE The AC ammeter gauge is controlled by the AC ammeter change-over switch. This switch is located on the control panel and does not affect the generator output. It is provided to help observe how much current is being supplied at the UOV terminal lugs.

  • Page 25: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UOV TERMINAL OUTPUT VOLTAGES 1Ø-120V Output Terminal Voltage 1. Connect the load wires to the output terminal lugs as 240/120V output voltages can be obtained using the output shown in Figure 14. terminal lugs. The voltage regulator (Figure 13) allows the user to GREEN BLACK WHITE...

  • Page 26: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK 5. If the engine oil level is low (Figure 16C), remove the oil filler cap (Figure 17) and fill to a safe operating level 1. To check the engine oil level, place the generator on (max) as indicated by the dipstick (Figure 16A). Fill with secure, level ground with the engine stopped.
  • Page 27 INSPECTION/SETUP FUEL CHECK Refueling Procedure DANGER WARNING Fuel spillage on a hot engine can cause Diesel fuel and its vapors are dangerous a fire or explosion. If fuel spillage occurs, to your health and the surrounding wipe up the spilled fuel completely to environment.
  • Page 28 INSPECTION/SETUP 3. NEVER overfill fuel tank — It is important to read the Day-to-day addition of coolant is done from the reserve fuel gauge when filling the trailer fuel tank. DO NOT tank. When adding coolant to the radiator, DO NOT remove wait for fuel to rise in the filler neck (Figure 21).
  • Page 29 INSPECTION/SETUP Cleaning The Radiator The fan belt tension is proper if the fan belt bends 0.22–0.24 in. (5.5–6.0 mm) when pressed with the thumb The engine may overheat if the radiator cooling fins as shown in Figure 26. (Figure 24) become overloaded with dust or debris. Periodically clean the radiator fins with compressed air.
  • Page 30 INSPECTION/SETUP Battery Cable Installation ALTERNATOR ALWAYS be sure the battery cables (Figure 27) are The polarity of the alternator is negative grounding type. properly connected to the battery terminals as shown below. When an inverted circuit connection takes place the circuit The red cable is connected to the positive terminal of the will be in short circuit instantaneously resulting in alternator battery, and the black cable is connected to the negative...

  • Page 31: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING STARTING (MANUAL) 1. Make sure the Diagnostic switch (located inside CAUTION the control box) is placed in the OFF position. See The engine’s exhaust contains harmful emissions. Figure 30. Make sure the control panel is closed ALWAYS have adequate ventilation when operating.
  • Page 32 GENERATOR START-UP PROCEDURE (MANUAL) 5. Once the engine starts, let the engine run for 10. If the voltage is not within the specified tolerance, use 1–2 minutes (longer in cold weather conditions). Listen the voltage regulator control knob (Figure 37) to for any abnormal noises.
  • Page 33 GENERATOR START-UP PROCEDURE (MANUAL) 14. The tachometer gauge (Figure 41) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1,800 rpm. RPMX10 SPEED Figure 41. Engine Tachometer Gauge 15. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 42).

  • Page 34: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING (AUTO MODE) When starting the generator in AUTO mode use the “Manual Start-up” procedure except where noted (see DANGER below). Before connecting this generator to any 1. Perform steps 1 through 5 in the Before Starting section building’s electrical system, a licensed as outlined in the Manual Starting Procedure.

  • Page 35: Generator Shutdown Procedures

    GENERATOR SHUTDOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE WARNING NOTICE NEVER stop the engine suddenly except in an emergency. The Emergency Stop Pushbutton Switch should only be used to stop the engine in case of an emergency NORMAL SHUTDOWN PROCEDURE or to lock out operation during service. The emergency stop switch should NEVER be used for routine stopping To shut down the generator, use the following procedure: of the engine.

  • Page 36: Maintenance

    MAINTENANCE 500 Hrs. 10 Hrs. Table 9. Inspection/Maintenance 250 Hrs. or Every 1,000 Hrs. OTHER DAILY 12 Months Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Air Cleaner Check Air Cleaner Element Check for Leaks/Hoses/Clamps Check for Loosening of Parts Drain Water in Fuel Change Engine Oil and Oil Filter * Clean Unit, Inside and Outside...
  • Page 37 MAINTENANCE GENERAL INSPECTION Primary And Secondary Air Cleaner Elements Prior to each use, the generator should be cleaned and Every 250 hours: Remove the air cleaner elements and inspected for deficiencies. Check for loose, missing or clean them with a light spray of compressed air. damaged nuts, bolts, or other fasteners.
  • Page 38 MAINTENANCE Air Cleaner Restriction Indicator Draining The Fuel Filter The air cleaner is equipped with a restriction indicator 1. Loosen the air bleeder plug (Figure 50) on the fuel (Figure 49). As the air cleaner element becomes clogged, filter body. air intake restriction increases and the indicator signal shows RED, indicating that the element needs to be replaced.
  • Page 39 MAINTENANCE Fuel Filter Element Replacement ELECTROMAGNETIC FUEL PUMP (500 HOURS) 1. Using a filter wrench, remove the element case from The filter inside the electromagnetic fuel pump (Figure 52) the fuel filter body (Figure 51). is either a paper type or steel mesh type depending on the fuel pump type.
  • Page 40 MAINTENANCE DRAINING THE CONTAINMENT TANK CLEANING INSIDE THE FUEL TANK 1. This generator is equipped with an environmental If necessary, drain the fuel inside the fuel tank completely. containment tank. Inspect this tank regularly. Using a spray washer (Figure 54), wash out any deposits or debris that have accumulated inside the fuel tank.
  • Page 41 MAINTENANCE DRAINING THE ENGINE OIL ENGINE OIL FILTER REPLACEMENT 1. Run the engine until the engine coolant reaches a 1. Clean the area around the oil filter head. temperature of 140°F (60°C). 2. Using an oil filter wrench (Figure 56), remove the 2.
  • Page 42 MAINTENANCE DRAINING THE ENGINE COOLANT 5. Flush out the radiator and replace the coolant. Refer to Cleaning the Coolant Passages and Filling the WARNING Coolant System in the Isuzu engine owner’s manual. DO NOT remove the pressure cap from the RADIATOR CLEANING radiator when the engine is hot! Wait until the coolant temperature is below 120°F...
  • Page 43 MAINTENANCE DRIVE BELT TESTING THE GFCI RECEPTACLE Drive Belt Tension NOTICE The GFCI receptacle is designed to interrupt power A slack drive belt may contribute to overheating or when a ground fault exists to prevent injuries and shock insufficient charging of the battery. Adjust the drive belt in hazards.
  • Page 44 MAINTENANCE GENERATOR STORAGE 4. Press the TEST button (Figure 63) on the GFCI receptacle and verify that the status LED turns OFF. For long-term storage of the generator the following is recommended: „ Drain the fuel tank completely. Treat with a fuel stabilizer if necessary.
  • Page 45 MAINTENANCE OPTIONAL ENGINE BLOCK HEATER When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the AND INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES idea to apply power to the heater at all times.
  • Page 46 MAINTENANCE EMISSION CONTROL PREVENTIVE MAINTENANCE PROGRAMS The emission control system employed with the Isuzu Most challenging to a rental organization is the fact that a 4LE2T diesel engine consists of a Diesel Oxidation Catalyst customer’s power assumptions may not meet the minimum (DOC).

  • Page 47: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) The engine controller of this generator diagnoses problems 6. Verify that the diagnostic lamp is ON. This indicates (faults/errors) that arise from the engine control system and that there is a fault/error in the engine or the engine the engine itself.

  • Page 48: Troubleshooting (Generator)

    TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 10 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 10.

  • Page 49: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) Symptom Possible Problem Solution No Fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump. Fuel fi lter clogged? Replace fuel fi lter and clean tank. Faulty fuel supply line? Replace or repair fuel line.
  • Page 50 TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air fi lter blocked? Clean or replace air fi lter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specifi cation. black exhaust smoke. Malfunction at injector? See engine manual.

  • Page 51: Generator Wiring Diagram (M1814000603B)

    GENERATOR WIRING DIAGRAM (M1814000603B) DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22) — PAGE 51...

  • Page 52: Engine Wiring Diagram (M1814100723)

    ENGINE WIRING DIAGRAM (M1814100723) PAGE 52 — DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22)

  • Page 53: Controller Wiring Diagram (M1814100803C)

    CONTROLLER WIRING DIAGRAM (M1814100803C) DCA20SPXU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #6 (09/07/22) — PAGE 53...

  • Page 54: Battery Charger Wiring Diagram (Option)

    BATTERY CHARGER WIRING DIAGRAM (OPTION) BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) AC POWER CORD TO CHASSIS GROUND 7.5 AMP TO STARTER “B” 7.5 AMP FUSE TERMINAL FUSE 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE.

  • Page 55: Engine Block Heater Wiring Diagram (Option)

    ENGINE BLOCK HEATER WIRING DIAGRAM (OPTION) BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) ENGINE BLOCK HEATER TEMP. BLACK 14 AWG. SWITCH LINE (L)120VAC INPUT HEATING 120 VAC ELEMENT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG.
  • Page 56 © COPYRIGHT 2022, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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