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DCA15SPXU4F • OPERATION MANUAL — REV. #1 (02/10/17) — PAGE 3

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 ....... 18

Output Terminal Panel Familiarization .............. 19-20

Load Application .................................................... 21

Gauge Reading/Terminal Panel Connections ........ 22

Setup ..................................................................... 23

Inspection/Setup ............................................... 24-26

Generator Start-Up Procedure ........................ 27-28

Generator Shutdown Procedure ........................... 29

Maintenance ..................................................... 30-33

Engine Fault Codes .............................................. 34

Troubleshooting Generator ................................... 35

Troubleshooting Engine .................................... 36-37

Generator Wiring Diagram ..................................... 38

Engine Wiring Diagram .......................................... 39

Battery Charger Wiring Diagram ........................... 40

Engine Block Heater Wiring Diagram .................... 41

Summary of Contents for WHISPERWATT Series

Page 1: ...L MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES To find the latest revision of this publication visit our website at www mqpower com WHISPERWATT SERIES MODEL DCA15SPXU4F 60Hz GENERATOR KUBOTA D1503 M DIESEL ENGINE Revision 1 02 10 17 ...

Page 2: ...PAGE 2 DCA15SPXU4F OPERATION MANUAL REV 1 02 10 17 PROPOSITION 65 WARNING Diesel engine exhaust and some of ...

Page 3: ...nel 16 17 Output Terminal Control Panel Familiarization 18 Output Terminal Panel Familiarization 19 20 Load Application 21 Gauge Reading Terminal Panel Connections 22 Setup 23 Inspection Setup 24 26 Generator Start Up Procedure 27 28 Generator Shutdown Procedure 29 Maintenance 30 33 Engine Fault Codes 34 Troubleshooting Generator 35 Troubleshooting Engine 36 37 Generator Wiring Diagram 38 Engine W...

Page 4: ...ages 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 which if n...

Page 5: ...ded by MQ Power for this equipment Damage to the equipment 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 invaluable in...

Page 6: ...amper with the factory settings of the engine or engine governor Damage to the engine or equipment 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 operate at ...

Page 7: ...ndition ALWAYS shutdown engine before transporting Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Trailer tires should be inflated to 50 psi co...

Page 8: ...pect for cuts in the insulation NEVER grab or touch a live power cord or cable with wet hands The possibility exists of electrical shock electrocution or death Make sure power cables are securely connected to the generator s output receptacles Incorrect connections may cause electrical shock and damage to the generator NOTICE ALWAYS make certain that proper power or extension cord has been selecte...

Page 9: ...uipment is over remove battery and bring to appropriate facility for lead reclamation Use safety precautions when handling batteries that contain sulfuric acid When the life cycle of this equipment is over it is recommended that the trowel frame and all other metal parts be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transformation in...

Page 10: ...7 lbs 620 kg Table 2 Engine Specifications Model Kubota D1503M Tier 4 Type 4 Cycle water cooled swirl combustion chamber type No of Cylinders 3 cylinders Bore x Stroke 3 23 in x 3 63 in 83 mm x 92 4 mm Displacement 91 47cu in 1 5 liter Rated Output 18 4 HP at 1800 rpm Starting Electric Coolant Capacity 1 85 gal 7 0 liters 1 Lube Oil Capacity 1 48 gal 5 6 liters 2 LubricatingType Oil SAE30 SAE20 SA...

Page 11: ...A15SPXU4F OPERATION MANUAL REV 1 02 10 17 PAGE 11 DIMENSIONS Table 3 Dimensions Reference Letter Dimension in mm A 20 08 510 B 21 65 550 C 18 11 460 D 56 3 1 430 E 25 6 650 F 35 4 900 Figure 1 Dimensions ...

Page 12: ...ATION MANUAL REV 1 02 10 17 INSTALLATION 8 MINIMUM GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND IF APPLICABLE GENERATOR GROUND LUG GROUND CABLE REFERENCE NEC 250 83 C Figure 2 Typical Generator Grounding Application ...

Page 13: ...tem may create sparks that can start fires and may cause abnormal combustion Therefore apply load gradually and observe the exhaust gas color MOUNTING The generator must be mounted on a solid foundation such as concrete and set firmly on the foundation to isolate vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to N...

Page 14: ... 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 rectified and are the excitation current for the exciter section When a heavy load such as a motor starting or a short circuit occurs the automatic voltage regulator AVR switches the configuration of the open delta to the series connecti...

Page 15: ...ITEM NO DESCRIPTION 1 Fuel Tank Assembly 2 Enclosure Assembly 3 Muffler Assembly 4 Engine And Radiator Assembly 5 Generator Assembly 5 Output Terminal Panel Assembly 6 Battery Assembly 7 Generator Control Panel Assembly 8 Auxiliary Receptacles Assembly 9 Output Terminal Board UNV Figure 3 Major Components ...

Page 16: ...rt up the lamp will go OFF If this lamp is ever lit ON during normal operation of the generator the emergency shutdown system will stop the engine automatically Figure 4 Engine Generator Control Panel B Water Temperature Alarm Lamp This lamp goes ON when the cooling water temperature rises abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown system will st...

Page 17: ...e 30 amp breaker provided to protect the L6 30R receptacle 11 Circuit Breaker Single pole 30 amp breaker provided to protect the L5 30R receptacle 12 Circuit Breaker Single pole 20 amp breaker provided to protect the GFCI receptacle 13 Main Circuit Breaker Three pole 70 amp main breaker provided to protect the U N and V output terminal lugs from overload NOTICE Remember the overcurrent relay monit...

Page 18: ...AL CONTROL PANEL FAMILIARIZATION OUTPUTTERMINAL 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 19: ... Receptacle There is one 120VAC 20 amp GFCI Duplex Nema 5 20R receptacle provided on the output terminal panel This receptacle is protected by a 20 amp circuit breaker The breaker can be located on the control panel Remember the load output current of both GFCI receptacles is dependent on the load requirements of the U O and V output terminal lugs Pressing the reset button resets the GFCI receptac...

Page 20: ...ent Relay An over current relay Figure 10 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Figure 10 Over Current Relay NOTICE Remember the overcurrent relay monitors ...

Page 21: ... approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage Table 5 Power Factor 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 Aninadequatesizeconnectingcablewhichcannotcarrythe require...

Page 22: ...either increases or decreases by monitoring the voltmeter Figure 13 reading Figure 13 AC Voltmeter Ammeter Gauge The ammeter gauge Figure 14 on the generator control panel has been provided to help observe how much current amps is being supplied to the load from the output terminal lugs GFCI receptacle or any auxulliary receptacles if installed Figure 14 Ammeter Load 1Ø 240 OutputTerminal Voltage ...

Page 23: ... oil for this generator When replacing engine oil please refill using Delo 400 LE SAE 15W 40 API CJ 4 engine oil Table 7 Recommended Motor Oil FUEL CHECK Refilling the Fuel System This generator has an internal fuel tank Figure 17 located inside the enclosure and may also be equipped with a trailer mountedfueltank ALWAYSfillthefueltankwithcleanfresh 2 diesel fuel DO NOT fill the fuel tank beyond i...

Page 24: ... Level Ground Unlevel Ground Level Ground Unlevel Ground DO NOT fill on unlevel ground 300 20 NOTICE ONLY use 2 diesel fuel when refueling 5 NEVER overfill fuel tank It is important to read the fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck Figure 20 Figure 20 Full Fuel Tank Figure 21 Fuel Expansion COOLANT ANTIFREEZE SUMMER COOLANT WATER Kubota recommends an...

Page 25: ... less than 50 FAN BELTTENSION A slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear and adjust it in accordance with the Isuzu Engine Owner s Manual The fan belt tension is proper if the fan belt bends 10 to 15 mm Figure 22 when depressed with the thumb as shown below Figure 22 Fan Belt Tension BATTERY This unit is of neg...

Page 26: ...he battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention tothepolarityofthebatterywhenconnectingthebattery ALTERNATOR The polarity of the alternator is negative grounding type When an inverted circuit connection takes place the circuit will be in short circuit instantaneously resulting the alternator failure DO NOT put water directly on the altern...

Page 27: ...uit breakers in the ON closed position INCORRECT CORRECT STARTING 1 Place the engine speed switch Figure 26 in the LOW down engine speed position Figure 26 Engine Speed Switch Low 2 Insert the ignition key into the ignition switch Turn the key clockwise to the PRE HEAT position Figure 27A and observe the pre heat lamp is ON Figure 27 Ignition Starter Switch 3 When the pre heat lamp has turned OFF ...

Page 28: ...Figure 31 Voltage Adjust Control Knob 9 The ammeter Figure 32 will indicate zero amps with no load applied When a load is applied the ammeter will indicate the amount of current that the load is drawing from the generator Figure 32 Ammeter No Load 10 Place the main GFCI and aux circuit breakers in the ON position Figure 33 Figure 33 Main Aux and GFCI Circuit Breakers ON 11 Observe the generator s ...

Page 29: ...e or loosening of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in an emergency EMERGENCY SHUTDOWN PROCEDURE 1 Turn the ignition key counterclockwise to the STOP position When the engine has stopped remove key Place key in a safe place where it will not be lost 2 Place both the MAIN GFCI and LOAD circuit breakers as shown in Figure 35 to the OFF p...

Page 30: ...rm the above procedures at shorter interval time 6 Applying a large load at one time to the unit when carbon deposits have accumulated in the exhaust system could produce fire sparks which could lead to abnormal combustion Therefore it is recommended to appy the load gradually and observe the exhaust gas color colorless during the process 7 Fire or sparks may emitt from the exhaust gas outlet duri...

Page 31: ...reakers in the OFF position Allow sufficient time for adequate cooling When ready to restart complete all steps in the Generator Startup Procedure section of this manual NOTICE The air filter should not be changed until the indicator reads RED Dispose of old air filter It may not be cleaned or reused If the engine is operating in very dusty or dry grass conditions a clogged air cleaner will result...

Page 32: ...stem CHECK OIL LEVEL Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 16 REPLACING OIL FILTER EVERY 200 HOURS Remove the old oil filter Apply a film of oil to the gasket on the new oil filter Install ...

Page 33: ...e optionally equipped with two 120 VAC 20 amp input receptacles located on the output terminal panel The purpose of these receptacles is to provide power via commercial power to the engine block heating element and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 42 To apply commercial power to these receptacles a power cord of ad...

Page 34: ...gine oil level and switch Low Battery Voltage Insufficient Charge Long 1 Short 3 Inspect or replace engine alternator voltage regulator High Water Temperature Overheat 234 F 112 C Approx Engine Shutdown Long 1 Short 4 Check coolant level and radiator Also check Temp switch Incorrect Crank Rotation Defective crank rotation sensor disconnection or short circuit Long 2 Short 1 Replace sensor check wi...

Page 35: ...nnections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Output Is wiring connections 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...

Page 36: ... too thick Refill engine crankcase with correct type of oil for winter environment Defective battery Replace battery Engine fires but stops soon as starter is switched off Fuel filter blocked Replace fuel filter Fuel supply blocked Check the entire fuel system Defective fuel pump Replace fuel pump Engine stops by itself during normal operation Fuel tank empty Add fuel Fuel filter blocked Replace f...

Page 37: ...h oil in engine crankcase Drain off engine oil down to uppermark on dipstick Entire cooling air system contaminated blocked Clean cooling air system and cooling fin areas Fan belt broken or elongated Change belt or adjust belt tension Coolant insufficient Replenish coolant Radiator net or radiator fin clogged with dust Clean net or fin carefully Fan radiator or radiator cap defective Replace defec...

Page 38: ...PAGE 38 DCA15SPXU4F OPERATION MANUAL REV 1 02 10 17 GENERATOR WIRING DIAGRAM ...

Page 39: ...DCA15SPXU4F OPERATION MANUAL REV 1 02 10 17 PAGE 39 ENGINE WIRING DIAGRAM ...

Page 40: ...PAGE 40 DCA15SPXU4F OPERATION MANUAL REV 1 02 10 17 BATTERY CHARGER WIRING DIAGRAM ...

Page 41: ...DCA15SPXU4F OPERATION MANUAL REV 1 02 10 17 PAGE 41 ENGINE BLOCK HEATER WIRING DIAGRAM ...

Page 42: ...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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