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 DCA15SPXU4F
60Hz GENERATOR
(KUBOTA D1503-M DIESEL ENGINE)
Revision #1 (02/10/17)
To find the latest revision of this
publication, 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 DCA15SPXU4F 60Hz GENERATOR (KUBOTA D1503-M DIESEL ENGINE) Revision #1 (02/10/17) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA15SPXU4F 60 Hz Generator Proposition 65 Warning ........... 2 Table Of Contents ............ 3 Safety Information ..........4-9 Specifications ............10 Dimensions ............11 Installation ............12-13 General Information ..........14 Major Components ..........15 Engine/Generator Control Panel....... 16-17 Output Terminal/Control Panel Familiarization ..

  • Page 4: Safety Information

    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 equipment will be referenced with hazard symbols which times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 5 SAFETY INFORMATION GENERAL SAFETY  NEVER use accessories or attachments that are not recommended by MQ Power for this equipment. Damage CAUTION to the equipment and/or injury to user may result.  NEVER operate this equipment without proper protective  ALWAYS know the location of the nearest clothing, shatterproof glasses, respiratory protection, fi...
  • Page 6 SAFETY INFORMATION ENGINE SAFETY NOTICE DANGER  NEVER run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter  The engine fuel exhaust gases contain poisonous carbon frequently to prevent engine malfunction.
  • Page 7 Safety Towing Regulations, before towing when towing. your generator.  Raise and lock trailer wheel stand in up position when  Refer to MQ Power trailer manual for additional safety towing. information.  Place chock blocks underneath wheel to prevent rolling ...
  • Page 8 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.  DO NOT touch output terminals during operation. Contact with output terminals NOTICE during operation can cause electrocution, ...
  • Page 9 SAFETY INFORMATION EMISSIONS INFORMATION  If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing NOTICE immediately with plenty of water. The diesel engine used in this equipment has been  If the battery liquid (dilute sulfuric acid) comes into designed to reduce harmful levels of carbon monoxide contact with eyes, rinse eyes immediately with plenty (CO), hydrocarbons (HC) and nitrogen oxides (NOx)

  • Page 10: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA15SPXU4F Revolving field, self ventilated, Type Drip-proof, single bearing Armature Connection Series Phase 1Ø Standby Output 14.7 kW (14.7 kVA) Prime Output 14 kW (14 kVA) 1Ø Voltage (L-L/L-N) 120/240 Voltage Selector Switch at 1Ø 240/120 Power Factor Frequency 60 Hz...

  • Page 11: Dimensions

    DIMENSIONS Figure 1. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Letter 20.08 (510) 21.65 (550) 18.11 (460) 56.3 (1,430) 25.6 (650) 35.4 (900) DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17) — PAGE 11...

  • Page 12: Installation

    INSTALLATION GENERATOR GROUND LUG GROUND ROD FOR EARTH GROUND. CONNECT TO BUILDING GROUND IF GROUND CABLE APPLICABLE N I M REFERENCE 8 ’ ( NEC 250-83 (C) Figure 2. Typical Generator Grounding Application PAGE 12 — DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17)
  • Page 13 INSTALLATION OUTDOOR INSTALLATION MOUNTING Install the generator in a area that is free of debris, The generator must be mounted on a solid foundation (such bystanders, and overhead obstructions. Make sure the as concrete) and set firmly on the foundation to isolate generator is on secure level ground so that it cannot slide vibration of the generator when it is running.

  • Page 14: General Information

    „ 3-pole 70 amp main circuit breaker Table 2 for engine specifications. „ 1-pole 20 amp breaker (for GFCI receptacle) In keeping with MQ Power’s policy of constantly improving „ 1-pole 30 amp breaker (for L5-30R receptacle) its products, the specifications quoted herein are subject „...

  • Page 15: Major Components

    MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION Fuel Tank Assembly Enclosure Assembly Muffler Assembly Engine And Radiator Assembly Generator Assembly Output Terminal Panel Assembly Battery Assembly Generator Control Panel Assembly Auxiliary Receptacles Assembly Output Terminal Board (UNV) Figure 3.

  • Page 16: Engine/Generator Control Panel

    ENGINE/GENERATOR CONTROL PANEL Figure 4. Engine/Generator Control Panel The definitions below describe the controls and functions B. Water Temperature Alarm Lamp — This lamp of the Engine/Generator Control Panel (Figure 4). goes ON when the cooling water temperature rises abnormally. If 1.
  • Page 17 ENGINE/GENERATOR CONTROL PANEL 5. Engine Speed Switch — This switch controls the speed of the engine low or high. 6. Hour Meter – Indicates amount of time generator has been in use. 7. Ignition/Starter Switch – Three position switch, stop, run and start.

  • Page 18: Output Terminal/Control Panel Familiarization

    OUTPUT TERMINAL/CONTROL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL The Output Terminal Panel (Figure 5) shown below is located on the left-hand side (below control panel) of the generator. Lift up on the cover to gain access output terminal lugs. Figure 5. Output Terminal/Control Panel PAGE 18 —...

  • Page 19: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacle L5-30R Receptacle There is one 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) There is one 120V, 30 amp auxiliary L5-30R receptacle receptacle provided on the output terminal panel. This (Figure 5) provided on the control panel. This receptacle can only be accessed when the main and associated circuit receptacle is protected by a 20 amp circuit breaker.
  • Page 20 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay An over current relay (Figure 10) is connected to the main Loads can be connected to the generator by various methods, output terminal lugs, camlocks or the convenience circuit breaker. In the event of an overload, both the circuit receptacles (Figure 9).

  • Page 21: 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 insure the wattage, amperage, frequency, current for starting than during operation. and voltage requirements are satisfactorily supplied by the An inadequate size connecting cable which cannot carry the generator for operating the equipment.

  • Page 22: Gauge Reading/Terminal Panel Connections

    GAUGE READING/TERMINAL PANEL CONNECTIONS UNV TERMINAL OUTPUT VOLTAGES Ammeter Gauge The ammeter gauge (Figure 14) on the generator 240/120V outout voltages can be obtained using the output control panel has been provided to help observe how terminal lugs. much current (amps) is being supplied to the load The voltage regulator (VR), Figure 12 allows the user to from the output terminal lugs, GFCI receptacle or any increase or decrease the selected voltage.

  • Page 23: Setup

    SETUP FUEL CHECK CIRCUIT BREAKERS Make sure to switch ALL circuit breakers to the OFF DANGER position prior to starting the engine. Fuel spillage on a hot engine can cause LUBRICATION OIL a fire or explosion. If fuel spillage occurs, Fill the engine crankcase with lubricating oil through the wipe up the spilled fuel completely to filler hole, but DO NOT overfill.

  • Page 24: Inspection/Setup

    INSPECTION/SETUP Refueling Procedure: 5. NEVER overfill fuel tank — It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait WARNING for fuel to rise in filler neck (Figure 20). Diesel fuel and its vapors are dangerous to your health and the surrounding environment.
  • Page 25 INSPECTION/SETUP FAN BELT TENSION Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove A slack fan belt may contribute to overheating, or to the radiator cap until the unit has completely cooled. See insufficient charging of the battery.
  • Page 26 INSPECTION/SETUP Battery Cable Installation CAUTION Inadequate battery connections may cause poor ALWAYS be sure the battery cables (Figure 23) are starting of the generator, and create other malfunctions. properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the ALTERNATOR battery, and the black cable is connected to the negative terminal of the battery.

  • Page 27: Generator Start-Up Procedure

    GENERATOR START-UP PROCEDURE BEFORE STARTING STARTING 1. Place the engine speed switch (Figure 26) in the LOW CAUTION (down) engine speed position. The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. Figure 26.
  • Page 28 GENERATOR START-UP PROCEDURE 6. The generator’s frequency meter (Figure 29) should 10. Place the main, GFCI, and aux. circuit breakers in the be displaying the 60 cycle output frequency in HERTZ. ON position (Figure 33). Figure 29. Frequency Meter 7. The generator’s AC-voltmeter (Figure 30) will display the generator’s output in VOLTS.

  • Page 29: Generator Shutdown Procedure

    GENERATOR SHUTDOWN PROCEDURE EMERGENCY SHUTDOWN PROCEDURE WARNING 1. Turn the ignition key counterclockwise to the STOP NEVER stop the engine suddenly except in an position. When the engine has stopped, remove key. emergency. Place key in a safe place where it will not be lost. NORMAL SHUTDOWN PROCEDURE 2.

  • Page 30: Maintenance

    MAINTENANCE 10 Hrs 1000 Table 10. Inspection/Maintenance 100 Hrs 200 Hrs 250 Hrs 400 Hrs 500 Hrs DAILY Check Engine Fluid Levels Check Fuel Level Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Change Engine Oil * Clean Air Filter Replace Engine Oil and Filter *...
  • Page 31 MAINTENANCE If the engine is operating in very dusty or dry grass NOTICE conditions, a clogged air cleaner will result. This can lead to Before inspecting generator, check that the ignition/ a loss of power, excessive carbon buildup in the combustion start switch is in the STOP position, and place all circuit chamber and high fuel consumption.
  • Page 32 MAINTENANCE FUEL TANK INSPECTION REPLACING OIL FILTER (EVERY 200 HOURS) In addition to cleaning the fuel tank, the following „ Remove the old oil filter. components should be inspected for wear: „ Apply a film of oil to the gasket on the new oil filter. „...
  • Page 33 MAINTENANCE RADIATOR CLEANING The purpose of these receptacles is to provide power via commercial power to the engine block heating element The radiator (Figure 41) should be sprayed (cleaned) with and internal battery charger. a high pressure washer when excessive amounts of dirt These receptacles will ONLY function when commercial and debris have accumulated on the cooling fins or tube.

  • Page 34: Engine Fault Codes

    ENGINE FAULT CODES ENGINE MALFUNCTION/FAILURE DIAGNOSTIC CODES When a engine malfunction/failure has been detected the engine will be shut down and the error code will be displayed on the glow plug warning lamp by a series of flashing patterns. The flashing patterns consist of a combination of one or more long flashes and one or more short flashes.

  • Page 35: 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 12 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 12.

  • Page 36: 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 37 TROUBLESHOOTING ENGINE (CONTINUED) 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 38: Generator Wiring Diagram

    GENERATOR WIRING DIAGRAM PAGE 38 — DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17)

  • Page 39: Engine Wiring Diagram

    ENGINE WIRING DIAGRAM DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17) — PAGE 39...

  • Page 40: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM PAGE 40 — DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17)

  • Page 41: Engine Block Heater Wiring Diagram

    ENGINE BLOCK HEATER WIRING DIAGRAM DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17) — PAGE 41...
  • Page 42 © COPYRIGHT 2017, 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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