MQ Power Whisperwatt DCA36SPXU4F Operation Manual Download

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OPERATION MANUAL

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

WHISPERWATT™ SERIES

MODEL DCA36SPXU4F

60Hz GENERATOR

(ISUZU 4LE2X DIESEL ENGINE)

Revision #4 (09/18/19)

Summary of Contents for Whisperwatt DCA36SPXU4F

Page 1: ...lication or associated parts manual visit our website at www mqpower com OPERATION MANUAL THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES WHISPERWATT SERIES MODEL DCA36SPXU4F 60Hz GENERATOR ISUZU 4LE2X DIESEL ENGINE Revision 4 09 18 19 ...

Page 2: ...PAGE 2 DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 PROPOSITION 65 WARNING ...

Page 3: ...oad Application 21 AC Ammeter Gauge Reading 22 Output Terminal Panel Connections 23 24 Inspection Setup 25 27 Generator Start Up Procedure Manual Mode 28 30 Generator Start Up Procedure Auto Mode 31 Generator Shut Down Procedures 32 Maintenance 33 36 Troubleshooting Diagnostics 37 Troubleshooting Generator 38 Troubleshooting Engine 39 40 Generator Wiring Diagram 41 Engine Wiring Diagram 42 Battery...

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: ...ier 4 Final Certified Type 4 Cycle water cooled direct injection turbocharged charge air cooled EGR and DOC No of Cylinders 4 cylinders Bore x Stroke 3 35 in x 3 78 in 85 mm x 96 mm Displacement 133 cu in 2 179 liter Rated Output 59 0 HP at 1800 rpm Starting Electric Coolant Capacity 4 4 gal 16 8 liters 1 Lube Oil Capacity 3 2 gal 12 2 liters 2 LubricatingType Oil API service class CJ 4 SAE or JAS...

Page 11: ...4 09 18 19 PAGE 11 DIMENSIONS Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 28 35 720 E 26 18 665 B 28 35 720 F 87 00 2 210 C 26 18 665 G 61 00 1 550 D 32 28 820 H 37 40 950 Figure 1 Dimensions ...

Page 12: ... EXAMPLEofhowtogroundtheunitifthecondition of use requires such a device The ground terminal on the generator should always be used to connect the generator to a suitable ground when required The ground cable should be 8 size wire aluminum minimum If copper wire is used 10 size wire minimum should be used Connect one end of the ground cable terminal to the generator ground point Figure 2 Connect t...

Page 13: ... 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 to provide ...

Page 14: ...ons 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 connection of B to C This has the effect of adding the voltages o...

Page 15: ...TION 1 Muffler Assembly 2 Output Terminal Board Assembly 3 Emergency Stop Switch Assembly Option 4 Output Terminal Panel Assembly 5 Generator Assembly 6 Battery Assembly 7 Engine Assembly 8 Fuel Tank Assembly 9 Gauge Unit Assembly 10 Generator Control Panel Assembly 11 Circuit Breaker Assembly Figure 3 Major Components ...

Page 16: ...ation This meter should indicate 1800 RPM s when the rated load is applied Figure 4 Engine Generator Control Panel F Warning LEDs Low Oil Pressure LED This LED will light when the engine oil pressure drops to 14 2 psi 98 kPa This condition will cause the engine to shut down High Temperature LED This LED will light when the coolant temperature has reached 212 F 100 C This condition will cause the e...

Page 17: ...p When the Auto Start Stop Switch is placed in the manual position this lamp will illuminate to indicate preheating of the engine glow plugs When the lamp turns off this indicates that the preheat cycle is complete and the engine can be started 11 Auto Start Stop Switch This switch selects either manual or automatic operation Center position is OFF reset 12 Engine Speed Switch This switch controls...

Page 18: ...p on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel Figure 5 is provided with the following Three 120 240 output receptacles 50 amps Three Aux Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amps Two GFCI Circuit Breakers 20 amps Four Output Terminal Lugs U O V ...

Page 19: ...tput terminal panel These receptacles can only be accessed when the main and auxiliary circuit breakers are in the ON position Figure 7 120 240V 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 all three receptacles is dependent on the load requireme...

Page 20: ...rent Relay An over current relay Figure 11 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 11 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: ...ided to help observe how much power is being supplied produced at the UOV terminal lugs AC Ammeter Gauge Reading Place the AC Ammeter Change Over Switch Figure 12 in the U position and observe the current reading load drain on the U terminal as indicated on the AC Ammeter Gauge This process can be repeated for terminal V Figure 12 Current Reading Load Drain NOTICE The ammeter gauge will only show ...

Page 23: ...ulator adjustment knob whenever fine tuning of the output voltage is required Figure 14 Voltage Regulator Knob U O V BLACK RED WHITE GREEN GROUND CONNECTION BE USED AT ALL TIMES MUST 240V SINGLE PHASE 240 VAC LOAD CONNECTIONS 1Ø 120 OutputTerminal Voltage Voltage 1 Connect the load wires to the output terminal lugs as shown in Figure 15 Figure 15 Output Terminal Lugs 1Ø 120V Connections 2 Turn the...

Page 24: ... by removing the oil drain plug and refill with the specified amount of oil as outlined in the Isuzu Engine Owner s Manual Oil should be warm before draining Delo engine oil is the recommended engine 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...

Page 25: ... can be pumped into the tank 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 COOLAN...

Page 26: ...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 nega...

Page 27: ...econnect negative terminal LAST POSITIVE NEGATIVE 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 alternator Entry of water into the alternator can cause corrosion and damage the alternator WIRING Inspect the ent...

Page 28: ...gine speed switch Figure 27 in the LOW down position Figure 27 Engine Speed Switch Low 3 Place the Auto Off Reset Manual Switch in the MANUAL position to start the engine Figure 28 Figure 28 Auto Off Reset Manual Switch Manual Position 4 Depending on the temperature of the coolant cold weather conditions the pre heat lamp Figure 29 will light ON and remain on until the pre heating cycle has been c...

Page 29: ...ntrol Knob 11 The ammeter Figure 34 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 34 Ammeter No Load 12 The engine oil pressure gauge Figure 35 will indicate the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 50 psi 345 kPa Figure ...

Page 30: ... 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 The ammeter will only display a current reading if a load is in use Figure 39 Ammeter Load 17 The generator will run until manually stopped or an abnormal condition occurs GENERATOR START UP PROCEDURE MANUAL MODE ...

Page 31: ... 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 32: ...ove all loads from the generator 6 Inspect entire generator for any damage or loosening of components that may have occurred during operation WARNING NEVER stop the engine suddenly except in an emergency EMERGENCY SHUTDOWN PROCEDURE 1 If equipped option push the Emergency Stop Pushbutton Switch Figure 43 Figure 43 Emergency Stop Button 2 If generator is not equipped with an emergency stop pushbutt...

Page 33: ...ion Filter 1500hrs Replace Air Cleaner Elements 3 As Required Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X MAINTENANCE 1 During initial operation of a new engine change oil and filter between a minimum of 100 hrs and a maximum of 250 hrs Service interval depends on type of oil 2 Add Supplemental Coolant Additives SCA S to recharge the engine coolant 3 R...

Page 34: ...breakers 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 resul...

Page 35: ...e exhaust stream into less harmful components In general this catalyst collects burns accumulated particulates The DOC contains palladiumandplatinumwhichserveasacatalyststooxidize hydrocarbons and carbon monoxide Replace DOC as required 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 th...

Page 36: ... 120VAC 20 amp input receptacle located on the output terminal panel The purpose of this receptacle is to provide power via commercial power to the internal battery charger and jacket water heater This receptacle will ONLY function when commercial power has been supplied to it Figure 47 To apply commercial power to this receptacle a power cord of adequate size will be required See Table 6 When usi...

Page 37: ...UMP SWITCH ON DIAGNOSTIC BUTTON 6 The following will occur The diagnostic lamp will start blinking with a pattern associated with the fault 3 times at an interval of 2 4 seconds If there are more than 2 fault codes are detected the diagnostic lamp will repeat the detected fault codes blinking patterns in ascending order After all the detected fault codes are shown it will repeat the same sequence ...

Page 38: ...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 39: ... 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 40: ...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 41: ...DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 PAGE 41 GENERATOR WIRING DIAGRAM ...

Page 42: ...PAGE 42 DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 ENGINE WIRING DIAGRAM ...

Page 43: ...DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 PAGE 43 BATTERY CHARGER WIRING DIAGRAM ...

Page 44: ...PAGE 44 DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 JACKET WATER HEATER WIRING DIAGRAM ...

Page 45: ...DCA36SPXU4F OPERATION MANUAL REV 4 09 18 19 PAGE 45 NOTES ...

Page 46: ...tained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Manufactured for MQ Power Inc by DENYO MANUFACTURING CO HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAN...

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