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 DCA40SSKU4F2
60 Hz GENERATOR
(KUBOTA V2403-CR-TIE4BG DIESEL ENGINE)
INSTRUCTION MANUAL NO. M1844300204
Revision #2 (08/30/22)
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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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA40SSKU4F2 60 Hz GENERATOR (KUBOTA V2403-CR-TIE4BG DIESEL ENGINE) INSTRUCTION MANUAL NO. M1844300204 Revision #2 (08/30/22) 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 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (08/30/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA40SSKU4F2 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 NOTICE Safety decals are attached to the generator as shown in For safety decal part numbers, refer to the associated Figure 1 . Keep these safety decals clean at all times. When parts manual. the safety decals become worn or damaged, contact your nearest dealer or the Multiquip Parts Department.

  • 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 DCA40SSKU4F2 Type Revolving field, protected type synchronous generator Armature Connection Star with Neutral Zigzag Phase Standby Output 30.2 kW (37.8 kVA) 27.3 kW Prime Output 28.8 kW (36 kVA) 26 kW 3Ø Voltage (L-L/L-N) 208Y/120, 220Y/127, 240Y/139 Voltage Selector Switch at 3Ø...

  • Page 12: Dimensions

    DIMENSIONS MAXIMUM TOP VIEW LIFTING POINT 5,150 LBS. (2,315 KG) SIDE VIEW FRONT VIEW Figure 2. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter 24.88 (632) 25.51 (648) M91020000 24.88 (632) 76.38 (1,940) 25.51 (648) 53.15 (1,350) 32.28 (820) 37.40 (950)
  • Page 13 NOTES DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (08/30/22) — 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 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (08/30/22)
  • 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

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

  • Page 17: Major Components

    MAJOR COMPONENTS 3 PHASE 240/139 3 PHASE 1 PHASE 480/277 240/120 PRESS TO LOCK Table 4. Generator Major Components ITEM NO. DESCRIPTION Voltage Selector Switch Assembly EC U Intergrated Gauge Control Air Cleaner Assembly Low Oil Pressre OFF/RESET High temp. PRESSURE HIGH COOLANT Over Crank...

  • Page 18: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL Intergrated Gauge Control Low Oil Pressre High temp. Over Crank Over Speed Engine Started INCREASE DECREASE Figure 5. Engine/Generator Control Panel 2. Auto START/STOP Controller (CAN 78) — This The definitions below describe the controls and functions controller has a vertical row of status LEDs (inset), that of the Engine/Generator Control Panel (Figure 5).
  • Page 19 ENGINE/GENERATOR CONTROL PANEL • Low Oil Pressure LED — This LED will light when the 13. Emergency Stop Switch (Option) — Push this button engine oil pressure drops to 14.2 psi. This condition inward to stop the engine in the event of an emergency. DO NOT use this button as a normal means of stopping will cause the engine to shut down.

  • 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 provided for the connection of electrical loads. Lift up on the following: the cover to gain access to receptacles and terminal lugs.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120-Volt AC GFCI Receptacles Twist-Lock Dual-Voltage 240/120 VAC Receptacles There are two 240/120V, 50-amp, auxiliary twist-lock NOTICE (CS-6369) receptacles (Figure 8) provided on the It is recommended that the GFCI receptacles be tested output terminal panel. These receptacles can only be when the generator is initially uncrated.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Overcurrent Relay An overcurrent relay (Figure 11) is connected to the Loads can be connected to the generator by the output terminal lugs, convenience receptacles, or optional main circuit breaker. In the event of an overload, both the cam-loks (Figure 10).

  • Page 23: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD THREE-PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to ensure the wattage, amperage, frequency, power use the following equation: and voltage requirements are satisfactorily supplied by the VOLTAGE ×...

  • Page 24: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES MAXIMUM AMPS Table 8 shows the maximum amps the generator can A wide range of voltages (Table 7) is available for many different applications. provide. DO NOT exceed the maximum amps as listed. Table 8. Generator Maximum Amps Table 7.

  • Page 25: Gauge Reading

    GAUGE READING HOW TO READ THE AC AMMETER AC Ammeter Gauge Reading AND AC VOLTMETER GAUGES The AC ammeter gauge is controlled by the AC ammeter change-over switch. Before taking a reading from either gauge, set the Voltage Selector Switch (Figure 14) to the position which produces This switch is located on the control panel and DOES NOT the required voltage.

  • Page 26: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator control knob (Figure 20) clockwise to increase voltage output, tur n Various output voltages can be obtained using the UVWO counterclockwise to decrease voltage output. Use the output terminal lugs.
  • Page 27 OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 22. position as shown in Figure 24.

  • Page 28: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK NOTICE 1. To check the engine oil level, place the generator on When adding engine oil DO NOT overfill (Figure 27B). secure, level ground with the engine stopped. 2. Remove the dipstick from its holder (Figure 26) and wipe it clean.
  • Page 29 INSPECTION/SETUP FUEL CHECK Refueling Procedure WARNING DANGER Diesel fuel and its vapors are dangerous Fuel spillage on a hot engine can cause to your health and the surrounding a fire or explosion. If fuel spillage occurs, environment. Avoid skin contact and/or wipe up the spilled fuel completely to prevent inhaling fumes.
  • Page 30 INSPECTION/SETUP 3. NEVER overfill the fuel tank — It is important to read NOTICE the fuel gauge when filling the trailer fuel tank. DO NOT Normally, only the coolant level in the reserve tank wait for fuel to rise in the filler neck (Figure 32). needs to be checked.
  • Page 31 INSPECTION/SETUP CLEANING THE RADIATOR FAN BELT TENSION The engine may overheat if the radiator cooling fins A slack fan belt may contribute to overheating, or to (Figure 35) become overloaded with dust or debris. insufficient charging of the battery. Inspect the fan belt for Periodically clean the radiator fins with compressed air.
  • Page 32 INSPECTION/SETUP BATTERY When connecting the battery: 1. NEVER connect the battery cables to the battery This unit is of negative ground. DO NOT connect in reverse. terminals when the Auto Start/Stop Switch is in either Always maintain battery fluid level between the specified the AUTO or MANUAL position.

  • Page 33: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING STARTING (MANUAL) 1. Place the voltage selector switch in the desired CAUTION voltage position (Figure 41). The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. 3 PHASE 240/139 Direct exhaust away from nearby personnel. 3 PHASE 1 PHASE 480/277...
  • Page 34 GENERATOR START-UP PROCEDURE (MANUAL) 9. The generator’s AC voltmeter (Figure 48) will display NOTICE the generator’s output in VOLTS. If the engine fails to start within a specified number of attempts, the shutdown lamp will illuminate and the Auto Start/Stop Switch must be placed in the Off/Reset position before the engine can be restarted.
  • Page 35 GENERATOR START-UP PROCEDURE (MANUAL) 13. Observe the generator’s ammeter (Figure 52) 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 52. Ammeter (Load) 14.

  • Page 36: 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 37: Generator Shutdown Procedures

    GENERATOR SHUTDOWN PROCEDURES NORMAL SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDURE WARNING NOTICE NEVER stop the engine suddenly except in an The Emergency Stop switch should only be used emergency. to stop the engine in case of an emergency or to lock out operation during service.

  • Page 38: Maintenance

    MAINTENANCE 500 Hrs 3,000 Hrs 10 Hrs Table 14. Inspection/Maintenance 250 Hrs or Every or Every OTHER DAILY 12 Months 36 Months Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Air Cleaner Visual Walk-Around Inspection Check for Leaks/Hoses/Clamps Check for Loosening of Parts Clean Air Element Element Change Engine Oil and Oil Filter *...
  • Page 39 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 40 MAINTENANCE ENGINE FUEL FILTER REPLACEMENT Draining The Fuel Water Separator 1. Clean the area around the fuel filter head. NOTICE 2. Using a filter wrench (Figure 59), remove the fuel filter. As water is collected, the red float goes up. When the float has reached the indicator mark (Figure 60), immediately drain the fuel water separator.
  • Page 41 MAINTENANCE CLEANING INSIDE THE FUEL TANK 3. Clean the inside of the cup with a light oil. 4. Clean the area around the fuel filter/water separator If necessary, drain the fuel inside the fuel tank completely. head. Using a spray washer (Figure 62) wash out any deposits or debris that have accumulated inside the fuel tank.
  • Page 42 MAINTENANCE DRAINING ENGINE OIL ENGINE OIL FILTER REPLACEMENT 1. Run the engine until the engine coolant reaches a 1. Clean the area around the lubricating oil filter head. temperature of 140°F (60°C). Turn the engine off. 2. Using an oil filter wrench (Figure 64), remove the 2.
  • Page 43 MAINTENANCE DRAINING ENGINE COOLANT FLUSHING OUT THE RADIATOR AND REPLACING COOLANT WARNING „ Open both cocks located at the crankcase side and at DO NOT remove the pressure cap from the radiator the lower part of the radiator and drain the coolant. Open when the engine is hot! Wait until the coolant the radiator cap while draining.
  • Page 44 MAINTENANCE RADIATOR CLEANING The radiator (Figure 67) 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.
  • Page 45 MAINTENANCE 3. Verify that the status LED on the corresponding GFCI 6. If the status LED (Figure 73) is flashing (RED), receptacle (Figure 70) is ON (GREEN). DO NOT use the GFCI receptacle. Replace it immediately. GREEN STATUS LED ( STATUS LED FLASHING Figure 70.
  • Page 46 MAINTENANCE ENGINE BLOCK HEATER AND When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES (OPTIONAL) idea to apply power to the engine block heater at all times.
  • Page 47 MAINTENANCE EMISSION CONTROL PREVENTIVE MAINTENANCE PROGRAMS The emission control system employed with the Kubota Most challenging to a rental organization is the fact that a diesel engine consists of a Diesel Oxidation Catalyst (DOC). customer’s power assumptions may not meet the minimum load requirements of the power equipment selected.

  • Page 48: Troubleshooting (Diagnostics)

    TROUBLESHOOTING (DIAGNOSTICS) The engine controller of this generator diagnoses problems 6. Verify that the Engine Shutdown lamp (Figure 77A) or Engine Pre-Alarm lamp (Figure 77B) is ON. This (faults/errors) that arise from the engine control system and the engine itself. indicates that there is a fault/error in the engine or the engine control system.

  • Page 49: 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 15 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 15.

  • Page 50: 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 51 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 52: Generator Wiring Diagram (M1814001203A)

    GENERATOR WIRING DIAGRAM (M1814001203A) PAGE 52 — DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (08/30/22)

  • Page 53: Engine Wiring Diagram (M1814102013)

    ENGINE WIRING DIAGRAM (M1814102013) DCA40SSKU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (08/30/22) — 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) TO CHASSIS GROUND GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

  • 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 WHITE 14 AWG. ELEMENT 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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