MQ Power DCA40SSKU4F2 Operation Manual Download Page 1

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THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Revision #0 (07/20/17)

OPERATION MANUAL

MODEL DCA40SSKU4F2

60Hz Whisperwatt™ Generator

(KUBOTA V2403-CR-TIE4BG DIESEL ENGINE)

Summary of Contents for DCA40SSKU4F2

Page 1: ...HE EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www mqpower com Revision 0 07 20 17 OPERATION MANUAL MODEL DCA40SSKU4F2 60Hz Whisperwatt Generator KUBOTA V2403 CR TIE4BG DIESEL ENGINE ...

Page 2: ...PAGE 2 DCA40SSKU4F2 60 HZ GENERATOR OPERATION MANUAL REV 0 07 20 17 PROPOSITION 65 WARNING Diesel engine exhaust and some of ...

Page 3: ...open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA ...

Page 4: ...rator Control Panel 20 Output Terminal Panel Familiarization 21 23 Load Application 24 Generator Outputs 25 Generator Outputs Gauge Reading 26 Output Terminal Panel Connections 27 28 Inspection Setup 29 32 Generator Start Up Procedure Manual 33 36 Generator Shut Down Procedures 37 Maintenance 38 45 Troubleshooting Diagnostics 46 Troubleshooting Generator Engine 47 Generator Wiring Diagram 48 Engin...

Page 5: ...DE VIEW 40 40 M92010000 WARNING ELECTRIC SHOCK HAZARD Do not touch internal wiring or connections while this machine is operating Turn power off before servicing This machine stops and starts automatically and without notice CAUTION M92010060 CAUTION DO NOT disconnect the Battery Cables after shutting down the engine for at least 30 seconds M90130000 FRONT VIEW M91020000 M92010070 WARNING ARC FLAS...

Page 6: ...ety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY WARNING Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY CAUTION Indicates a hazardous situation wh...

Page 7: ...ecommended by MQ Power for this generator Damage to the generator and or injury to user may result ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest first aid kit ALWAYS know the location of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invalu...

Page 8: ... NEVER tamper with the factory settings of the engine or engine governor Damage to the engine or generator can result if operating in speed ranges above the maximum allowable Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied When a diesel engine operates without sufficient load less than 40 of the rated output it will not ope...

Page 9: ...it breakers OFF before performing maintenance on the generator or making contact with output terminals NEVER insert any objects into the output receptacles during operation This is extremely dangerous The possibility exists of electrical shock electrocution or death Backfeed to a utility system can cause electrocution and or property damage NEVER connect the generator to a building s electrical sy...

Page 10: ...ose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur WARNING ALWAYS wear safety glasses when handling the battery to avoid eye irritation The battery contains acids that can cause injury to the eyes and skin Use well insulated gloves when picking up the bat...

Page 11: ...ame and all other metal parts be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product Recyclers and manufacturers alike promote the process of recycling metal Using a metal recycling center promotes energy cost savings EMISSIONS INFORMATION NOTICE The diesel engine used in...

Page 12: ...y 60 Hz Speed 1800 rpm Aux AC Power Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 Dry Weight 2 205 lbs 1 000 kg Wet Weight 2 735 lbs 1 240 kg Table 2 Engine Specifications Model Kubota V2403 CR TIE4BG Tier 4 Final Certified Type 4 cycle water cooled direct injection turbocharged EGR ECM and DOC No of Cylinders 4 cylinders Bore x Stroke 3 42 x 4 01 in 87 x 102 mm Displacement 149 in3 2 43...

Page 13: ...W H G A E D B TOP VIEW SIDE VIEW C 40 M91020000 MAXIMUM LIFTING POINT 5 150 LBS 2 315 KG Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 24 88 632 E 25 51 648 B 24 88 632 F 76 38 1 940 C 25 51 648 G 53 15 1 350 D 32 28 820 H 37 40 950 ...

Page 14: ... 07 20 17 INSTALLATION GENERATOR GROUND LUG GROUND CABLE REFERENCE NEC 250 8 FT 2 4 M MINIMUM IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD Figure 2 Typical Generator Grounding Application ...

Page 15: ...r They are to resist damage to the bottom of the generator and to maintain alignment CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area GENERATOR GROUNDING if applicable to guard against electrical shock and possible damage to the equipment it is important t...

Page 16: ...stem The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four connections of the open delta A B C and D During steady state loads the power from the voltage regulator is supplied from the parallel connections of A to B A to D and C to D These three phases of the voltage input to the voltage regulator are then recti...

Page 17: ... 1 3 9 7 6 2 Low Oil Pressre High temp Over Crank Over Speed Engine Started ECU Intergrated Gauge Control R Figure 3 Major Components Table 4 Generator Major Components ITEM NO DESCRIPTION 1 Voltage Selector Switch Assembly 2 Air Cleaner Assembly 3 Muffler Assembly 4 Fuel Tank Assembly 5 Fuel Drain Plug 6 Engine Radiator Assembly 7 Coolant Drain Plug 8 Output Terminal Panel Assembly 9 Generator As...

Page 18: ...e LED will turn on b EnginePreAlarmLED Indicatesthatanengine failure has occured LED will turn on or blink c Battery Charge Alarm LED This LED is ON when the output voltage of the alternator drops below a set value If this lamp is ON during normal operation the emergency shutdown system will immediately stop the engine d Fuel Filter Water Level LED This LED is ON when the water level in the fuel f...

Page 19: ...ne temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault and the engine will be shut down C Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of times and has failed to start The number of cycles and duration are programmable It is pre set at 3 cycles with a 10 second duration This is considered...

Page 20: ...itch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals or to be switched off This switch does not effect the generator output in any fashion it is for current reading only 6 Voltage Regulator Control Allows 15 manual adjustment of the generator s output voltage 7 Emergency Stop Button Option Push this button inward to stop the engine i...

Page 21: ... provided with the following Two 120 240V output receptacles CS6369 50 amp Two Auxiliary Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amp Two Duplex Circuit Breakers 20 amps Five Output Terminal Lugs U V W O Ground AUX POWER RECEPTACLES 240 120V 50 AMPS 120 VAC 20 AMP GFCI RECEPTACLES Y X W CS 6369 TWIST LOCK CIRCUIT BREAKERS FOR GFCI RECEPTACLES RECEPTACLE AND CIRCUIT BREAKER PANEL HARD ...

Page 22: ...panel These receptacles can only be accessed when the voltage selector switch is placed in the single phase 240 120 position Figure 8 240 120V Twist Lock Auxiliary Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on both auxiliary receptacles is dependent on the load requir...

Page 23: ...When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size Over Current Rela...

Page 24: ...ctor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 THREE PHASE LOAD When calculating the power requirements for 3 phase power use the following equation Aninadequatesizeconnectingcablewhichcannotcarrythe required load can c...

Page 25: ...9V Position Voltage Selector Switch 3 Phase 480 270V Position 3Ø Line Line 208V 220V 240V 416V 440V 480V 1Ø Line Neutral 120V 127V 139V 240V 254V 277V Voltage Selector Switch Single Phase 240 120V Position 1Ø Line Neutral Line Line 120V Line Neutral N A N A 240V Line Line N A N A Generator Amperage Table 8 shows the maximum amps the generator can provide DO NOT exceed the maximum amps as listed GF...

Page 26: ...gure 14 Voltage Selector Switch 240 139V 3Ø Position AC Voltmeter Gauge Reading Place the ACVoltmeter Change Over Switch Figure 15 in theW U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the ACVoltmeter Gauge Figure 16 NOTICE For 3Ø 208V 1Ø 120V place the Voltage Selector Switch in the 3 Phase 240 139 position Figure 15 AC Voltmeter Change Ov...

Page 27: ...Switch 3Ø 240 139V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 20 Figure 20 UVWO Terminal Lugs 3Ø 240 139V Connections 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required Figure 21 Voltage Regulator...

Page 28: ...egulator adjustment knob whenever fine tuning of the output voltage is required 1Ø 240 120V UVWOTerminal Output Voltages 1 Place the voltage selector switch in the 1Ø 240 120 position as shown in Figure 26 Figure 26 Voltage Selector Switch 1Ø 240 120V Position 2 Connect the load wires to the UVWO terminals as shown in Figure 27 Figure 27 UVWO Terminal Lugs 1Ø 200 100V Connections 3 Turn the voltag...

Page 29: ...oil as outlined in the KUBOTA Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD API Service Classification CC SE API Service Classification CC SF Table 11 Recommended Motor Oil FUEL CHECK Refilling the Fuel System This generator has an intern...

Page 30: ...and maximize the amount of fuel that can be pumped into the tank Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel ground 150 40 NOTICE ONLY use low sulfur or ultra low sulfur diesel fuel when refueling 2 Open cabinet doors on the right side of the generator from generator control panel position Remove fuel cap and fill tank as shown in Figure 31 Figure 31 Fueling the ...

Page 31: ...e 12 Coolant Capacity Engine and Radiator 4 75 gal 18 liters Reserve Tank N A Table 13 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point Boiling Point C F C F 50 37 34 108 226 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 CLEANINGTHE RADIATOR The engine may overheat if the radiator fins become overloaded with dust or debris Periodica...

Page 32: ...ect negative terminal LAST POSITIVE NEGATIVE When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position ALWAYS make sure that the MPEC Control Switch is in the OFF RESET position when connecting the battery 2 Place a small amount of battery terminal treatment compound around both battery termina...

Page 33: ...m nearby personnel WARNING NEVERmanuallystarttheenginewiththemain duplex or auxiliary circuit breakers in the ON closed position MAIN CIRCUIT BREAKER DUPLEX CIRCUIT BREAKERS CS 6369 AUX CIRCUIT BREAKERS OFF OFF OFF OFF OFF OFF OFF INCORRECT CORRECT STARTING MANUAL 1 Place the voltage selector switch in the desired voltage position Figure 38 Figure 38 Voltage Selector Switch 2 Place the engine spee...

Page 34: ...ntergrated Gauge Control R NOTICE If the engine fails to start after 3 attempts the over crank LED on the ECU controller will turn on and the Auto Off Reset Switch must be placed in the Off Reset position before the engine can be restarted HIGH UP 8 The generator s frequency meter Figure 44 should be displaying the 60 cycle output frequency in HERTZ Figure 44 Frequency Meter 9 The generator s AC v...

Page 35: ...e generator s ammeter Figure 49 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 49 Ammeter Load 14 The generator will run until manually stopped or an abnormal condition occurs MAIN CIRCUIT BREAKER DUPLEX CIRCUIT BREAKERS CS 6369 AUX CIRCUIT BREAKERS ON ON ON ON ON ON ON GENERATOR START UP PRO...

Page 36: ... to your ATS installation manual for further instructions for the correct installation of the auto start contacts of the generator to the ATS WARNING When running the generator in the AUTO mode rememberthegeneratorcanstartupatanytimewithout warning NEVER attempt to perform any maintenance when the generator is in the auto mode NOTICE When the Auto Off Reset Manual switch is placed in the AUTO posi...

Page 37: ...R stop the engine suddenly except in an emergency MAIN CIRCUIT BREAKER DUPLEX CIRCUIT BREAKERS CS 6369 AUX CIRCUIT BREAKERS OFF OFF OFF OFF OFF OFF OFF LOW DOWN AUTO MANUAL OFF RESET EMERGENCY SHUTDOWN PROCEDURE 1 If equipped option push the Emergency Stop Pushbutton Switch Figure 54 Figure 54 Emergency Stop Button 2 If unit is not equipped with an emergency stop switch place the Auto Off Reset Ma...

Page 38: ...est Cooling System X Check Engine Speed X Test Thermostat 6000 hrs Check and Adjust EngineValve Clearance X Test Glow Plugs X Replace Diesel Oxidation Catalyst DOC 2 4500 hrs Flush and Refill Cooling System 2yrs or2000hrs Clean Inside of Fuel Tank 1000hrs Check Crankcase Ventilation Filter X Replace Air Cleaner Elements 3 As Required Generator Measure Insulation Resistance Over 3M ohms X Check Rot...

Page 39: ...with loose or damaged components NOTICE If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result This can lead to a loss of power excessive carbon buildup in the combustion chamber and high fuel consumption Change air cleaner more frequently if these conditions exist CAUTION Wear protective equipment such as approved safety glasses or face shields and dust...

Page 40: ...the indicator mark Figure 57 immediately drain the fuel water separator 2 Loosen the screw at the top of the filter head and also loosen the drain cock located at the bottom of the filter 3 Let the residue or foreign substances inside the cup flow into a suitable container 4 Tighten screw and place fuel valve lever in the OPEN position Figure 57 Fuel Filter Water Separator Cleaning Fuel Water Sepa...

Page 41: ...ng FuelTank Lining inspect the fuel tank lining for signs of excessive amounts of oil or other foreign matter Loosen the drain plug at the lower top of the fuel filter Drain the fuel in the fuel body together with the mixed FUEL TANK V BELT DAILY Visually examine the V belt Figure 59 and determine if it is full of tiny cracks frayed has pieces of rubber missing is peeling or is otherwise damaged A...

Page 42: ...40 15W 40 20W 20 30 40 OIL SAE DRAIN BOLT SEALING WSHER NOTICE For composite oil pans always install a new sealing washer MAINTENANCE ENGINE OIL FILTER REPLACEMENT 1 Clean the area around the lubricating oil filter head 2 Using an oil filter wrench Figure 62 remove engine oil filter Figure 62 Engine Oil Filter Removal 3 Coat the rubber seal gasket surface of oil filter Figure 62 with clean 15W 40 ...

Page 43: ...d DO NOT clean radiator core with any objects such as a screwdriver WARNING DO NOT remove the pressure cap from the radiator when the engine is hot Wait until the coolant temperature is below 120 F 50 C before removing pressure cap Heated coolant spray or steam can cause severe scalding and personal injury DRAIN BOLT RADIATOR CLEANING The radiator Figure 64 should be sprayed cleaned with a high pr...

Page 44: ...er heater at all times If the generator will be used daily the battery should normally not require charging If the generator will be idle not used for long periods of time apply power to the battery charger receptacle via commercial power using a power cord of adequate size GENERATOR STORAGE For long term storage of the generator the following is recommended Drain the fuel tank completely Treat wi...

Page 45: ...iculates TheDOCcontains palladium and platinum which serve as a catalysts to oxidize hydrocarbons and carbon monoxide EMISSION CARBON CHECK Deposition of carbon soot unburned fuel in the exhaust pipe line and muffler could cause not only system derates but also could lead to fires To reduce soot and unburned fuel run the unit at rated power until the exhaust gas become mostly colorless every 250 h...

Page 46: ... this generator diagnoses problems that arise from the engine control system and the engine itself ON OFF DIAGNOSTIC SWITCH ENGINE SHUTDOWN PRE ALARM FLASHING If no fault code is detected the pre alarm diagnostic LED will blink repeatedly at an interval of 2 4 seconds 5 When diagnostic verfication is complete be sure to place the diagnostic switch in the OFF position Figure 69 The engine will not ...

Page 47: ...ons loose Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace Table 17 Engine GeneratorTroubleshooting Pre Alarm LED Type of Fault Possible Fault Pre Alarm LED Indica...

Page 48: ... WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTAT CURRENT TRANSFORMER CHANGE OVER SWITCH AMMETER AC AMMETER AC VOLTMETER FREQUENCY METER CIRCUIT BREAKER 3P 110A CIRCUIT BREAKER 2P 50A CIRCUIT BREAKER 1P 20A RECEPTACLE CS6369 250 VAC 50 AMPS RECEPTACLE GFCI 125 VAC 20 AMPS X 2 OVER CURRENT RELAY SELE...

Page 49: ... ２５１２５２２４９２５５２５６２５３２５４ＳＨ２ＳＨ１ＶＢＧＮＤ１１２１１１ B L G V P R W Y O BR GR LB LG WIRE COLOR BLACK BLUE BROWN GREEN GRAY VIOLET PINK ORANGE LIGHT GREEN LIGHT BLUE YELLOW WHITE RED SYM SYM WIRE COLOR COLOR CODE ２５３２５５２５６ＳＨ２ＳＨ１ＧＮＤＶＢ１５５１５４１５０１５１１５６１５３１５２１４９２５０２５４２５２２５１ ...

Page 50: ... AWG NEMA 5 15 15A 120 VAC P N HBL5278C HUBBLE RECEPTACLE NOTES 1 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY 20 AMP 5 20R RECEPTACLE P N HBL5369C HUBBLE RECEPTACLE 3 4 CORD CAROL 3 C 14 AWG P N EE56557 120 VAC INPUT INSERT EXTERNAL POWER CORD HERE 3 1 2 4 BLACK 14 AWG LINE L 120VAC INPUT WHITE 14 AWG NEUTRAL N GREEN 14 AWG GROUND G 1 2 3 4 A B A B ...

Page 51: ...8C HUBBLE RECEPTACLE BLACK 14 AWG LINE L 120VAC INPUT WHITE 14 AWG NEUTRAL N GREEN 14 AWG GROUND G NOTES 1 2 RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY 20 AMP 5 20R RECEPTACLE P N HBL5369C HUBBLE RECEPTACLE 3 4 CORD CAROL 3 C 14 AWG P N EE56557 120 VAC INPUT INSERT EXTERNAL POWER CORD HERE 3 1 2 4 BLACK 14 AWG LINE L 120VAC INPUT WHITE 14 AWG NEUTRAL N GREEN 14 AWG GROUND G 1 2 3 4 A B A ...

Page 52: ...co uk Tel 0161 339 2223 Fax 0161 339 3226 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 This manual MUST accompany the equipment at all times This manual is considered...

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