MULTIQUIP Power WHISPERWATT DCA-15SPX4 Operation And Parts Manual Download

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Revision #0(02/17/09)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

WHISPERWATT

SERIES

MODEL DCA-15SPX4

60 Hz GENERATOR

Summary of Contents for Power WHISPERWATT DCA-15SPX4

Page 1: ...PARTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 0 02 17 09 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 15SPX4 60 Hz GENERATOR...

Page 2: ...PAGE 2 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 Diesel engine exhaust and some of PROPOSITION 65WARNING...

Page 3: ...DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 PAGE 3 1 NOTE PAGE...

Page 4: ...25 Gauge Reading Terminal Panel Connections 26 Setup 27 30 Generator Start up Procedure 31 32 Generator Shut Down Procedure 33 Maintenance Engine 34 36 Maintenance Trailer 37 39 GeneratorWiring Diagra...

Page 5: ...om To obtain an MQ Account contact your Order via Internet Dealers Only Orderpartson lineusingMultiquip sSmartEquipwebsite View Parts Diagrams Order Parts Note Discounts Are Subject To Change Gotowww...

Page 6: ...e l g n i S C A V 0 4 2 W K 2 1 z H 0 6 e s a h P e l g n i S C A V 0 2 1 W K 6 s n o i t a c i f i c e p S e n i g n E 2 e l b a T l e d o M M 3 0 2 2 V A T O B U K e p y T e p y t r e b m a h c n o...

Page 7: ...S N O I S N E M I D 3 E L B A T r e t t e L e c n e r e f e R m m t f n o i s n e m i D A m m 0 5 5 n i 5 6 1 2 B m m 0 9 4 n i 9 2 9 1 C m m 5 1 6 n i 1 2 4 2 D m m 5 1 4 1 n i 0 7 5 5 E m m 2 0 9 n...

Page 8: ...SLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions Gasoline engine exhaust gases co...

Page 9: ...lothing away from all moving parts to prevent injury WARNING ROTATING PARTS Wet Stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied W...

Page 10: ...nt due to equipment modifications Unauthorized equipment modification will void all warranties NEVER use accessories or attachments which are not recommended by Multiquip for this equipment Damage to...

Page 11: ...ed to a suitable earth ground GROUND ROD See installation in this manual NEVER use gas piping as an electrical ground Maintenance Safety NEVERlubricatecomponentsorattemptserviceonarunning machine High...

Page 12: ...To avoid severe injury or DEATH DO NOT drop the battery There is the possibility of risk that the battery may explode DO NOT expose the battery to open flames sparks cigarettes etc The battery contain...

Page 13: ...ctions may cause damage to the generators and electrical shock NEVER insert any objects into the output receptacles during operation This is extremely dangerous ALWAYS turn off the generators and plac...

Page 14: ...ure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of safety precautions should be followed whe...

Page 15: ...DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 PAGE 15 1 NOTE PAGE...

Page 16: ...PAGE 16 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 Figure 2 Typical Generator Grounding Application DCA 15SPX4 INSTALLATION...

Page 17: ...larger b Aluminum 8 AWG 8 4 mm2 or larger 2 When grounding the generator Figure 2 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the o...

Page 18: ...gsteadystateloads thepowerfromthevoltageregulator 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 rectif...

Page 19: ...I R C S E D 1 y l b m e s s A r e t l i F r i A 2 y l b m e s s A r e l f f u M 3 y l b m e s s A r o t a i d a R d n a e n i g n E 4 y l b m e s s A r o t a r e n e G 5 y l b m e s s A y r e t t a B...

Page 20: ...EV 0 02 17 09 Figure 4 Generator Control Panel DCA 15SPX4 GENERATOR CONTROL PANEL U N V 14 A V HZ WATER TEMP OIL PRESS BATT LOW LEVEL BATT LOW LEVEL DECREASE INCREASE PREHEAT LAMP PREHEAT LAMP 3 1 2 7...

Page 21: ...tch controls the speed of the engine from idle to high 7 Starter Switch This switch has four positions A Stop The switch should be in this position anytime the unit is not in operation This position a...

Page 22: ...ptacle 120V GFCI receptacle 20 amps L5 30R receptacle 125V 30 amps L6 30R receptacle 240V 30 amps Three OutputTerminal Lugs U N V and Ground OutputTerminal Panel TheOutputTerminalPanel Figure5 shownbe...

Page 23: ...ing the knob counter clockwise will decrease the voltage Figure 7 120 240V CS6369Twist Lock Auxiliary Receptacle DCA 15SPX4 OUTPUT TERMINAL PANEL FAMILIARIZATION Twist Lock DualVoltage120 240VAC Recep...

Page 24: ...r the convenience receptacles Figure 11 Make sure to read the operation manual before attempting to connect a load to the generator To protect the output terminals from overload a 3 pole 70A main circ...

Page 25: ...can cause a voltage drop which can burn out the appliance or tool and overheat the cable See Table 6 NOTE Before connecting this generator to any building s electrical system a licensed electrician m...

Page 26: ...to decrease voltage output 1 120 OutputTerminal Lug Voltages 1 Connect the load wires to the OutputTerminal Lugs as shown in Figure 12 Figure 12 OutputTerminal Lugs 120VAC Single Phase Connections Am...

Page 27: ...nd verify that the oil level is maintained between the two notches Figure 17 on the dipstick See Table 8 for proper selection of engine oil Figure 18 Internal FuelTank System Refilling the Fuel System...

Page 28: ...Fuel Tank Figure 22 Fuel Expansion 2 Remove fuel cap internal fuel tank and fill fuel tank as shown Figure 20 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximiz...

Page 29: ...negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the KUBOTA Engine Owner s Manual Fan BeltTension A slack fan belt may contri...

Page 30: ...any hose fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close attention to the polarity of the b...

Page 31: ...d position WARNING STARTINGTHE GENERATOR Figure 26 Engine Enclosure Doors Figure 29 Frequency Meter Hz 3 Once the engine starts let it engine run for 1 2 minutes Listen for any abnormal noises If any...

Page 32: ...e 34 9 Observe the generator s ammeter Figure 35 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 Figu...

Page 33: ...n in Figure 27 and let the engine cool for 3 5 minutes with no load applied 3 Turn the ignition key counter clockwise to the STOP position When the engine has stopped remove key Place key in a safe pl...

Page 34: ...After changing the air element press the dust indicator button to reset the indicator E C N A N E T N I A M N O I T C E P S N I 1 1 E L B A T s r H 0 1 Y L I A D s r H 0 5 2 s r H 0 0 5 s r H 0 0 0 1...

Page 35: ...sassembling the fuel system bleed the system according to the following procedure See the KUBOTA Engine Manual for details To restart after running out of fuel turn the switch to the ON position for 1...

Page 36: ...nction when commercial power has been supplied to them Figure 36 To apply commercial power to these receptacles a power cord of adequate size will be required See Table 6 When using the generator in h...

Page 37: ...rakingrequirestheinstallationofanactuator at the tongue of the trailer Remember the surge or push of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehic...

Page 38: ...ening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 14 Figure 38 Major Suspension Components DCA 15SPX4 TRAILER MAINTENANCE DO NOT at...

Page 39: ...wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 39 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as d...

Page 40: ...PAGE 40 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 GENERATORWIRING DIAGRAM Figure 40 GeneratorWiring Diagram...

Page 41: ...DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 PAGE 41 1 DCA 15SPX4 ENGINEWIRINGDIAGRAM Figure 41 Engine Wiring Diagram...

Page 42: ...o n n o i t c e j n i n a e l C g n i n o i t c n u f l a m p m u p n o i t c e j n I e c a l p e r r o r i a p e R t f a h s m a c t f a h s k n a r c f o e r u z i e S g n i r a e b r o r e n i l r...

Page 43: ...n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m o c t n e i c i f e D e c n a r a e l...

Page 44: ...R e v i t c e f e D e c a l p e r d n a k c e h C d l e i F r e t i c x E e v i t c e f e D 1 N C n o K J s s o r c a s m h o 3 7 1 r o f k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e...

Page 45: ...r o h s t r o h S 1 g n o L 2 d i o n e l o S t i u c r i c t r o h s n o i t c e n n o c s i D t r o h S 2 g n o L 2 e r u t a r e p m e T r e t a W r o s n e S n o i t c e n n o c s i D t r o h S 4...

Page 46: ...and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale...

Page 47: ...1584139010 SWITCH OIL 1 1949883040 SWITCH THEROMETER 1 0810105900 FILTER FUEL 6 1522143172 FILTER FUEL CARTRIDGE 6 1641432433 FILTER OIL CARTRIDGE 3 0602046335 FILTER AIR ELEMENT 1 LY2DUS12VDC RELAY 1...

Page 48: ...PAGE 48 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 GENERATOR ASSY...

Page 49: ...0000 WASHER LOCK 4 1 10 0601000209 BALANCING WEIGHT KIT 1 1 11 0071906308 BEARING 1 6308DDUC3 2 0070506903 BEARING 1 6903ZZ 3 0012808035 HEX HEAD BOLT 6 5 B0130101103 STATOR ASSY 1 5 1 0845041904 GROM...

Page 50: ...PAGE 50 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 CONTROL PANEL ASSY DCA 15SPX4 CONTROL PANEL ASSY...

Page 51: ...BRACKET 1 11 1 0222100115 RUBBER CUSHION 1 12 0021806015 MACHINE SCREW 2 13 1628663602 STARTER SWITCH 1 REPLACES P N 0602100077 13A 3741055150 KEY STARTER SWITCH 14 0601810523 WARNING LAMP UNIT 1 14A...

Page 52: ...PAGE 52 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 CONTROL PANEL ASSY DCA 15SPX4 CONTROL PANEL ASSY...

Page 53: ...SCREW 2 32A 0040005000 WASHER LOCK 2 32B 0041205000 WASHER FLAT 2 33 B0214600404 FUSE BOX 1 33A 0601806642 FUSE 5A 5 33B 0601806645 FUSE 10A 4 33C B0551002104 DECAL FUSE BOX 1 34 0027105015 MACHINE S...

Page 54: ...PAGE 54 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY...

Page 55: ...6 0039508000 HEX NUT 3 7 0039508000 HEX NUT 3 8 7831860104 RUBBER SEAL 1 9 0016906020 HEX HEAD BOLT 4 10 0601815109 GROUNDTERMINAL 1 11 7671865403 COVER OUTPUTTERMINAL 1 11 1 7671865804 RUBBER SHEET 1...

Page 56: ...PAGE 56 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 57: ...TOR 1 6 1 0602011079 RADIATOR CAP 1 7 0220300400 RUBBER SEAL 2 8 B1311100204 BRACKET RADIATOR 1 9 0016908030 HEX HEAD BOLT 2 10 B1312100923 BRACKET RADIATOR 1 11 B1312600004 MOUNT RUBBER 2 12 00169080...

Page 58: ...PAGE 58 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 59: ...20 HEX HEAD BOLT 1 33 B0321100304 DRAIN HOSE 1 34 0605515064 HOSE BAND 2 35 0199900500 DRAIN HOSE 1 36 0199900370 DRAIN HOSE 1 37 0605515094 HOSE BAND 4 38 0802081403 RESERVE TANK 1 39 0802081104 CAP...

Page 60: ...PAGE 60 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 BATTERY ASSY BATTERY ASSY...

Page 61: ...REMARKS 1 0165308026 BATTERY 1 80D26R 2 B1345200114 BATTERY BAND 1 3 0805002904 BATTERY BOLT 2 4 0037808000 WING NUT 2 5 0040008000 WASHER LOCK 2 6 0041208000 WASHER FLAT 2 7 0845040414 TERMINAL CAP 1...

Page 62: ...PAGE 62 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 MUFFLER ASSY MUFFLER ASSY...

Page 63: ...NO PART NO PART NAME QTY REMARKS 1 B1331101113 MUFFLER 1 2 0016908020 HEX HEAD BOLT 5 3 B1334000703 EXHAUST PIPE 1 4 1732612231 GASKET 1 REPLACES P N 0602320153 5 0207008000 HEX NUT 4 6 0602325008 PIP...

Page 64: ...PAGE 64 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 FUELTANK ASSY FUEL TANK ASSY...

Page 65: ...HEAD BOLT 2 8 0037908000 HEX NUT 2 9 7812014003 DRAIN JOINT 1 10 0802011104 PLUG 1 11 0150000018 O RING 1 12 0016906015 HEX HEAD BOLT 2 13 0199901400 DRAIN HOSE 1 14 0605515094 HOSE BAND 2 15 1522143...

Page 66: ...PAGE 66 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 ENCLOSURE ASSY ENCLOSURE ASSY...

Page 67: ...COVER FRONT FRAME 1 8A B0495100404 LINING 1 9 0016908020 HEX HEAD BOLT 6 10 B1434300703 HANGER 1 11 B0434300503 HANGER 1 12 0012312030 HEX HEAD BOLT 8 13 B0444004002 REAR FRAME 1 14 0016908020 HEX HE...

Page 68: ...PAGE 68 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 ENCLOSURE ASSY ENCLOSURE ASSY...

Page 69: ...04 LINING 1 34 B0454001003 SIDE DOOR 1 34A B0494400704 LINING 1 35 B1454300804 DUCT 1 36 0207006000 HEX NUT 6 37 B9114000002 DOOR HANDLE 1 38 0021806016 MACHINE SCREW 4 39A 0845045004 WASHER 2 40 0845...

Page 70: ...PAGE 70 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 RUBBER SEAL ASSY RUBBER SEALS ASSY...

Page 71: ...KS 1 0229200650 RUBBER SEAL 1 2 0221700620 RUBBER SEAL 2 3 0221701035 RUBBER SEAL 2 4 0229400675 RUBBERSEAL 2 5 0229401040 RUBBER SEAL 2 6 0229200590 RUBBER SEAL 2 7 0229200255 RUBBER SEAL 2 8 0229400...

Page 72: ...PAGE 72 DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 DCA 15SPX4 NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY...

Page 73: ...3823A 19 7670650004 DECAL DANGER HIGH VOLTAGE 1 S 3956 20 7560615004 DECAL STARTER SWITCH 1 S 4547 21 B0551001803 DECAL OPERATING PROCEDURE 1 B05100180 22 B9504000304 DECAL CAUTION HOT PARTS 1 B09400...

Page 74: ...Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 8 Such material will be held for five workingdaysfromnotification pending instru...

Page 75: ...DCA 15SPX4 OPERATION MANUAL REV 0 02 17 09 PAGE 75 1 NOTE PAGE...

Page 76: ...mation and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for gui...

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