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MQ Power Whisperwatt DCA36SPXU4F Operation Manual

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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL DCA36SPXU4F
60Hz GENERATOR
(ISUZU 4LE2X DIESEL ENGINE)
Revision #4 (09/18/19)
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 DCA36SPXU4F

  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA36SPXU4F 60Hz GENERATOR (ISUZU 4LE2X DIESEL ENGINE) Revision #4 (09/18/19) 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 — DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA36SPXU4F 60 Hz Generator Proposition 65 Warning ........... 2 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 Panel Familiarization ..... 18–20 Load Application ............

  • 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 DCA36SPXU4F Revolving field, self ventilated, Type Drip-proof, single bearing Armature Connection Star with Neutral Phase 1Ø Standby Output 40 kW (40 kVA) Prime Output 36 kW (36 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) Reference Letter Dimension in. (mm) Letter 28.35 (720) 26.18 (665) 28.35 (720) 87.00 (2,210) 26.18 (665) 61.00 (1,550) 32.28 (820) 37.40 (950) DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19) — PAGE 11...

  • Page 12: Installation

    INSTALLATION CONNECTING THE GROUND The ground cable should be #8 size wire (aluminum) minimum. If copper wire is used, #10 size wire minimum Consult with local Electrical and Safety Codes for proper should be used. connection based on condition of use. Connect one end of the ground cable terminal to the EXAMPLE of how to ground the unit if the condition generator ground point (Figure 2).
  • Page 13 INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the The Occupational Safety and Health Administration generator is on secure level ground so that it cannot slide (OSHA) and the National Electrical Code (NEC) or shift around.

  • Page 14: General Information

    „ 3-Pole, 150 amp Main Circuit Breaker generator. Reference Table 2 for engine specifications. „ “Control Box” (located behind Control Panel) In keeping with MQ Power’s policy of constantly improving • Automatic Voltage Regulator its products, the specifications quoted herein are subject •...

  • Page 15: Major Components

    MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION Muffler Assembly Output Terminal Board Assembly Emergency Stop Switch Assembly (Option) Output Terminal Panel Assembly Generator Assembly Battery Assembly Engine Assembly Fuel Tank Assembly Gauge Unit Assembly Generator Control Panel Assembly Circuit Breaker Assembly 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 F. Warning LEDs of the Engine/Generator Control Panel (Figure 4). • Low Oil Pressure LED — This LED will light 1. Gauge Unit Assembly — This assembly houses the when the engine oil pressure drops to 14.2 psi various engine monitoring gauges.
  • Page 17 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 18: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 5) shown below is The “Output Terminal Panel ” (Figure 5) is provided with located on the right-hand side (left from control panel) of the following: the generator.
  • Page 19 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the There are two 120 VAC, 20 amp GFCI (Duplex Nema GFCI receptacles. Remember the load output (current) on 5-20R) receptacles provided on the output terminal panel.
  • Page 20 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay An over current relay (Figure 11) 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 10).

  • 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: 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 effect the generator output. It is provided to help observe how much power is being supplied, produced at the UOV terminal lugs.

  • Page 23: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UOV TERMINAL OUTPUT VOLTAGES 1Ø-120 Output Terminal Voltage Voltage 1. Connect the load wires to the output terminal lugs as 240/120V outout voltages can be obtained using the output shown in Figure 15. terminal lugs. The voltage regulator (VR), Figure 14 allows the user to GREEN BLACK WHITE...
  • Page 24 OUTPUT TERMINAL PANEL CONNECTIONS FUEL CHECK CIRCUIT BREAKERS To protect the generator from an overload, a 3-pole, 150 DANGER amp, main circuit breaker is provided to protect the U, O, Fuel spillage on a hot engine can cause and V Output Terminals from overload. In addition, two a fire or explosion.

  • Page 25: 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 26 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 27 INSPECTION/SETUP Battery Cable Installation NOTICE ALWAYS be sure the battery cables (Figure 23) are If the battery cable is connected incorrectly, electrical properly connected to the battery terminals as shown below. damage to the generator will occur. Pay close attention The red cable is connected to the positive terminal of the to the polarity of the battery when connecting the battery.

  • Page 28: Generator Start-Up Procedure (Manual Mode)

    GENERATOR START-UP PROCEDURE (MANUAL MODE) BEFORE STARTING 2. Place the engine speed switch (Figure 27) in the LOW (down) position. CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. Figure 27. Engine Speed Switch (Low) WARNING 3.
  • Page 29 GENERATOR START-UP PROCEDURE (MANUAL MODE) 7. If the engine is running smoothly, place the engine speed switch (Figure 30) in the HIGH (up) position. Figure 30. Engine Speed Switch (High) Figure 34. Ammeter (No Load) 8. The generator’s frequency meter (Figure 31) should 12.
  • Page 30 GENERATOR START-UP PROCEDURE (MANUAL MODE) 15. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 38). Figure 38. Main, Aux. and GFCI Circuit Breakers (ON) 16. Observe the generator’s ammeter (Figure 39) and verify it reads the anticipated amount of current with respect to the load.

  • Page 31: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START-UP PROCEDURE (AUTO MODE) NOTICE DANGER The engine speed switch must be set to the “High” Before connecting this generator to any position when running in the auto-start mode. Failing building’s electrical system, a licensed electrician must install an isolation to set the switch in the proper position can result in (transfer) switch.

  • Page 32: Generator Shut-Down Procedures

    GENERATOR SHUT-DOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE WARNING 1. If equipped (option), push the Emergency Stop NEVER stop the engine suddenly except in an Pushbutton Switch (Figure 43). emergency. NORMAL SHUTDOWN PROCEDURE To shutdown the generator, use the following procedure: 1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 41 to the OFF position.

  • Page 33: Maintenance

    MAINTENANCE 500 Hrs 3000 Hrs 10 Hrs Table 10. 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/Element Exhaust System* Check for Leaks/Hoses/Clamps* Check for Loosening of Parts Change Engine Oil and Oil Filter * Clean Unit, Inside and Outside...
  • Page 34 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 Auto/ a loss of power, excessive carbon buildup in the combustion Manual switch is in the OFF/RESET position, and place chamber and high fuel consumption.
  • Page 35 MAINTENANCE FUEL TANK INSPECTION CHECK OIL LEVEL Check the crankcase oil level prior to each use, or when the In addition to cleaning the fuel tank, the following fuel tank is filled. Insufficient oil may cause severe damage components should be inspected for wear: to the engine.
  • Page 36 MAINTENANCE RADIATOR CLEANING The purpose of this receptacle is to provide power via commercial power to the internal battery charger and jacket The radiator (Figure 46) should be sprayed (cleaned) with water heater. a high pressure washer when excessive amounts of dirt This receptacle will ONLY function when commercial power and debris have accumulated on the cooling fins or tube.

  • Page 37: Troubleshooting Diagnostics

    TROUBLESHOOTING DIAGNOSTICS The engine controller of this generator diagnoses problems 6. The following will occur: that arise from the engine control system and the engine „ The diagnostic lamp will start blinking with a pattern itself. Press the diagnostic button on the diagnostic panel associated with the fault 3 times at an interval of 2.4 (Figure 48) to determine if an engine malfunction has seconds.

  • Page 38: 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 11 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 11.

  • Page 39: 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 40 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 41: Generator Wiring Diagram

    GENERATOR WIRING DIAGRAM DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19) — PAGE 41...

  • Page 42: Engine Wiring Diagram

    ENGINE WIRING DIAGRAM PAGE 42 — DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19)

  • Page 43: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19) — PAGE 43...

  • Page 44: Jacket Water Heater Wiring Diagram

    JACKET WATER HEATER WIRING DIAGRAM PAGE 44 — DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19)
  • Page 45 NOTES DCA36SPXU4F • OPERATION MANUAL — REV. #4 (09/18/19) — PAGE 45...
  • Page 46 © COPYRIGHT 2019, 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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