Multiquip Automobile Parts DCA20SPXU2 User Manual

OperatiOn and parts Manual  
WhisperWatt™ series  
MOdel dca20spxu2  
60hz generatOr  
(isuzu BV-4le2 diesel engine)  
Used with MLt20 series Light towers onLy  
parts list nO. M1870301404  
Revision #0 (01/18/13)  
To find the latest revision of this  
publication, visit our website at:  
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.  
pn 49840  
Download from Www.Somanuals.com. All Manuals Search And Download.  
prOpOsitiOn 65 Warning  
Diesel engine exhaust and some of  
page 2 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
repOrting safety defects  
If you believe that your vehicle has a defect that could cause a crash or could  
cause injury or death, you should immediately inform the National Highway  
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at  
1-800-421-1244.  
If NHTSA receives similar complaints, it may 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  
write to:  
Administrator  
NHTSA  
1200 New Jersey Avenue S.E.  
Washington, DC 20590  
You can also obtain information about motor vehicle safety from  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 3  
Download from Www.Somanuals.com. All Manuals Search And Download.  
taBle Of cOntents  
dca20spxu2 60 hz generator  
Proposition 65 Warning ........................................... 2  
Reporting Safety Defects......................................... 3  
Table Of Contents.................................................... 4  
Parts Ordering Procedures...................................... 5  
Safety Information .............................................. 6-11  
Specifications ........................................................ 12  
Dimensions............................................................ 13  
Installation ........................................................ 14-15  
General Information............................................... 16  
Major Components ................................................ 17  
Generator Control Panel........................................ 18  
Engine Control Panel........................................ 20-21  
Output Terminal Panel Familiarization.............. 22-24  
Load Application/Generator Output....................... 25  
Output Terminal Panel Connections ...................... 26  
Inspection/Setup............................................... 27-30  
Generator Start-Up Procedure (Manual) ......... 31-32  
Generator Start-Up Procedure (Auto) ................... 33  
Generator Shut-Down Procedures ........................ 34  
Maintenance..................................................... 35-38  
Trailer Maintenance .......................................... 39-42  
Trailer Wiring Diagram ........................................... 43  
Generator Wiring Diagram..................................... 44  
Engine Wiring Diagram.......................................... 45  
Troubleshooting (Generator).................................. 46  
Explanation Of Code In Remarks Column............. 48  
Suggested Spare Parts ......................................... 49  
component drawings  
Generator Assembly......................................... 50-51  
Control Box Assembly....................................... 52-55  
Engine And Radiator Assembly........................ 56-59  
Output Terminal Assembly................................ 60-61  
Battery Assembly.............................................. 62-63  
Muffler Assembly.............................................. 64-65  
Fuel Filter Assembly......................................... 66-67  
Enclosure Assembly......................................... 68-71  
Rubber Seals Assembly ................................... 72-73  
Nameplate and Decals Assembly .................... 74-75  
Terms And Conditions Of Sale — Parts ................ 76  
page 4 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
parts Ordering prOcedures  
Ordering parts has never been easier!  
choose from three easy options:  
Effective:  
January 1st, 2006  
Best Deal!  
order via internet (Dealers only):  
Order parts on-line using Multiquip’s SmartEquip website!  
If you have an MQ Account, to obtain a Username  
and Password, E-mail us at: parts@multiquip.  
com.  
I View Parts Diagrams  
I Order Parts  
I Print Specification Information  
To obtain an MQ Account, contact your  
District Sales Manager for more information.  
Use the internet and qualify for a 5% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
to log in and save!  
Order Parts  
Note: Discounts Are Subject To Change  
Fax your order in and qualify for a 2% Discount  
on Standard orders for all orders which include  
complete part numbers.*  
order via Fax (Dealers only):  
All customers are welcome to order parts via Fax.  
Domestic (us) Customers dial:  
1-800-6-PARTS-7 (800-672-7877)  
Note: Discounts Are Subject To Change  
Domestic (us) Dealers Call:  
order via phone:  
1-800-427-1244  
non-Dealer Customers:  
International Customers should contact  
their local Multiquip Representatives for  
Parts Ordering information.  
Contact your local Multiquip Dealer for  
parts or call 800-427-1244 for help in  
locating a dealer near you.  
When ordering parts, please supply:  
Ì
Dealer account number  
Ì
specify preferred Method of shipment:  
Ì
Ì
Ì
Ì
Ì
Dealer name and address  
UPS/Fed Ex  
DHL  
Truck  
I
I
Priority One  
Ground  
shipping address (if different than billing address)  
return Fax number  
I Next Day  
Second/Third Day  
applicable Model number  
I
Quantity, part number and Description of each part  
NOTICE  
All orders are treated as Standard Orders and will  
ship the same day if received prior to 3PM PST.  
we aCCepT all MaJor CreDiT CarDs!  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 5  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
Do not operate or service the equipment before reading the  
entire manual. Safety precautions should be followed at all  
times when operating this equipment. Failure to read and  
understand the safety messages and operating instructions  
could result in injury to yourself and others.  
Potential hazards associated with the operation of this  
equipment will be referenced with hazard symbols which  
may appear throughout this manual in conjunction with  
safety messages.  
saFeTY Messages  
The four safety messages shown below will inform you  
about potential hazards that could injure you or others.The  
safety 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 which, if not avoided,  
CoulD result in Minor or MoDeraTe inJurY.  
NOTICE  
Addresses practices not related to personal injury.  
page 6 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
„ never use accessories or attachments that are not  
recommended by MQ Power for this equipment.Damage  
to the equipment and/or injury to user may result.  
general saFeTY  
CauTion  
„ never operate this equipment without proper protective  
clothing, shatterproof glasses, respiratory protection,  
hearing protection, steel-toed boots and other protective  
devices required by the job or city and state regulations.  
„ 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  
the case of an emergency.  
„ never operate this equipment when not  
feeling well due to fatigue, illness or when  
under medication.  
„ never operate this equipment under the influence of  
drugs or alcohol.  
generaTor saFeTY  
Danger  
„ neveroperatetheequipmentinanexplosive  
atmosphereornearcombustiblematerials.An  
explosion or fire could result causing severe  
bodily harm or even death.  
„ alwaYs check the equipment for loosened threads or  
bolts before starting.  
„ Do noT use the equipment for any purpose other than  
its intended purposes or applications.  
warning  
„ never disconnect any emergency or safety devices.  
These devices are intended for operator safety.  
Disconnection of these devices can cause severe injury,  
bodily harm or even death.Disconnection of any of these  
devices will void all warranties.  
NOTICE  
„ This equipment should only be operated by trained and  
qualified personnel 18 years of age and older.  
„ Whenever necessary, replace nameplate, operation and  
safety decals when they become difficult read.  
CauTion  
„ Manufacturer does not assume responsibility for any  
accident due to equipment modifications. Unauthorized  
equipment modification will void all warranties.  
„ never lubricate components or attempt service on a  
running machine.  
NOTICE  
„ alwaYs ensure generator is on level ground before use.  
„ alwaYs keep the machine in proper running condition.  
„ Fix damage to machine and replace any broken parts  
immediately.  
„ alwaYs store equipment properly when it is not being  
used.Equipment should be stored in a clean, dry location  
out of the reach of children and unauthorized personnel  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 7  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
engine saFeTY  
Danger  
NOTICE  
„ never run engine without an air filter or with a dirty air  
filter.Severe engine damage may occur.Service air filter  
frequently to prevent engine malfunction.  
„ The engine fuel exhaust gases contain poisonous carbon  
monoxide. This gas is colorless and odorless, and can  
cause death if inhaled.  
„ never tamper 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.  
„ The engine of this equipment  
requires an adequate free  
flow of cooling air. never  
operate this equipment in  
any enclosed or narrow area  
where free flow of the air is  
restricted. If the air flow is  
restricted it will cause injury to people and property and  
serious damage to the equipment or engine.  
„ 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 its optimum temperature. This will allow  
unburned fuel to accumulate in the exhaust system,  
which can foul the fuel injectors, engine valves and  
exhaust system, including turbochargers, and reduce  
the operating performance.  
warning  
„ Do noT place hands or fingers inside engine  
compartment when engine is running.  
In order for a diesel engine to operate at peak efficiency,  
it must be able to provide fuel and air in the proper ratio  
and at a high enough engine temperature for the engine  
to completely burn all of the fuel.  
„ never operate the engine with heat shields or  
guards removed.  
„ Keep fingers, hands hair and clothing away  
from all moving parts to prevent injury.  
Wet stacking does not usually cause any permanent  
damage and can be alleviated if additional load is  
applied to relieve the condition.It can reduce the system  
performance and increase maintenance. Applying an  
increasing load over a period of time until the excess  
fuel is burned off and the system capacity is reached  
usually can repair the condition. This can take several  
hours to burn off the accumulated unburned fuel.  
„ Do noT remove the radiator cap while the  
engine is hot. High pressure boiling water  
will gush out of the radiator and severely  
scald any persons in the general area of  
the generator.  
„ Do noT remove the coolant drain plug while the engine  
is hot. Hot coolant will gush out of the coolant tank and  
severely scald any persons in the general area of the  
generator.  
„ State Health Safety Codes and Public Resources  
Codes specify that in certain locations, spark arresters  
must be used on internal combustion engines that use  
hydrocarbon fuels.A spark arrester is a device designed  
to prevent accidental discharge of sparks or flames  
from the engine exhaust. Spark arresters are qualified  
and rated by the United States Forest Service for this  
purpose. In order to comply with local laws regarding  
spark arresters, consult the engine distributor or the  
local Health and Safety Administrator.  
„ Do noT remove the engine oil drain plug while the  
engine is hot. Hot oil will gush out of the oil tank and  
severely scald any persons in the general area of the  
generator.  
CauTion  
„ never touch the hot exhaust manifold,  
muffler or cylinder.Allow these parts to cool  
before servicing equipment.  
page 8 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
„ Make sure the hitch and coupling of the towing vehicle  
are rated equal to, or greater than the trailer “gross  
vehicle weight rating.”  
Fuel saFeTY  
Danger  
„ Do noT start the engine near spilled fuel or combustible  
fluids. Diesel fuel is extremely flammable and its vapors  
can cause an explosion if ignited.  
„ 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 cold.  
Also check the tire tread wear on both vehicles.  
„ alwaYs refuel in a well-ventilated area, away from  
sparks and open flames.  
„ alwaYs use extreme caution when working with  
flammable liquids.  
„ alwaYs make sure the trailer is equipped with a safety  
chain.  
„ Do noT fill the fuel tank while the engine is running  
or hot.  
„ alwaYs properly attach trailer’s safety chains to towing  
vehicle.  
„ Do noT overfill tank, since spilled fuel could ignite if it  
comes into contact with hot engine parts or sparks from  
the ignition system.  
„ alwaYs make sure the vehicle and trailer directional,  
backup, brake and trailer lights are connected and  
working properly.  
„ Store fuel in appropriate containers, in well-ventilated  
areas and away from sparks and flames.  
„ DOT Requirements include the following:  
• Connect and test electric brake operation.  
„ never use fuel as a cleaning agent.  
• Secure portable power cables in cable tray with tie  
wraps.  
„ Do noT smoke around or near the  
equipment. Fire or explosion could result  
from fuel vapors or if fuel is spilled on a  
hot engine.  
„ The maximum speed for highway towing is55 Mphunless  
posted otherwise.Recommended off-road towing is not to  
exceed 15 Mph or less depending on type of terrain.  
Towing saFeTY  
CauTion  
„ Avoid sudden stops and starts.This can cause skidding,  
or jack-knifing. Smooth, gradual starts and stops will  
improve towing.  
„ Check with your local county or state safety  
towing regulations, in addition to meeting  
Department of Transportation (DOT)  
SafetyTowing Regulations, before towing  
your generator.  
„ Avoid sharp turns to prevent rolling.  
„ Trailer should be adjusted to a level position at all times  
when towing.  
„ Raise and lock trailer wheel stand in up position when  
towing.  
„ Refer to MQ Power trailer manual for additional safety  
information.  
„ Place chock blocks underneath wheel to prevent rolling  
while parked.  
„ In order to reduce the possibility of an accident while  
transporting the generator on public roads, alwaYs  
make sure the trailer that supports the generator and  
the towing vehicle are mechanically sound and in good  
operating condition.  
„ Place support blocks underneath the trailer’s bumper  
to prevent tipping while parked.  
„ Use the trailer’s swivel jack to adjust the trailer height to  
a level position while parked.  
„ alwaYs shutdown engine before transporting  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
„ Make sure power cables are securely connected to the  
generator’s output receptacles. Incorrect connections  
may cause electrical shock and damage to the  
generator.  
eleCTriCal saFeTY  
Danger  
„ Do noT touch output terminals during  
operation. Contact with output terminals  
duringoperationcancauseelectrocution,  
electrical shock or burn.  
NOTICE  
„ alwaYs make certain that proper power or extension  
cord has been selected for the job. See Cable Selection  
Chart in this manual.  
„ The electrical voltage required to  
operate the generator can cause severe  
grounding safety  
Danger  
injury or even death through physical contact with live  
circuits. Turn generator and all circuit breakers oFF  
before performing maintenance on the generator or  
making contact with output terminals.  
„ alwaYs make sure that electrical circuits are properly  
grounded to a suitable earth ground (ground rod) per  
the National Electrical Code (NEC) and local codes  
before operating generator. severe injury or death by  
electrocution can result from operating an ungrounded  
generator.  
„ never insert any objects into the output  
receptacles during operation. This is  
extremely dangerous.The possibility exists  
of electrical shock, electrocution or  
death.  
„ never use gas piping as an electrical ground.  
„ Backfeed to a utility system can cause  
electrocution and/or property damage.  
never connect the generator to a  
building’s electrical system without  
a transfer switch or other approved  
device. All installations should be  
performed by a licensed electrician in accordance with  
all applicable laws and electrical codes. Failure to do so  
could result in electrical shock or burn, causing serious  
injury or even death.  
power Cord/Cable safety  
Danger  
„ never let power cords or cables lay in water.  
„ never stand in water while AC power from the  
generator is being transferred to a load.  
„ never use damaged or worn cables or cords when  
connecting equipment to generator. Inspect 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.  
page 10 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
safety infOrMatiOn  
BaTTerY saFeTY  
Danger  
environMenTal saFeTY  
NOTICE  
„ Do noT drop the battery. There is a possibility that the  
battery will explode.  
„ Dispose of hazardous waste properly.  
Examples of potentially hazardous waste  
are used motor oil, fuel and fuel filters.  
„ Do noT expose 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.  
„ Do noT use food or plastic containers to  
dispose of hazardous waste.  
„ Do noT pour waste, oil or fuel directly onto the ground,  
down a drain or into any water source.  
warning  
„ alwaYswearsafetyglasseswhenhandling  
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 battery.  
„ alwaYs keep the battery charged. If the battery is not  
charged, combustible gas will build up.  
„ alwaYs recharge the battery in a well-ventilated  
environmenttoavoidtheriskofadangerousconcentration  
of combustible gasses.  
„ If the battery liquid (dilute sulfuric acid) comes into  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
„ If the battery liquid (dilute sulfuric acid) comes into  
contact with eyes, rinse eyes immediately with plenty  
of water and contact the nearest doctor or hospital to  
seek medical attention.  
CauTion  
„ alwaYs disconnect the negaTive battery terminal  
before performing service on the generator.  
„ alwaYs keep battery cables in good working condition.  
Repair or replace all worn cables.  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
specificatiOns  
Table 1. generator specifications  
DCA-20SPXU2  
Model  
Type  
Revolving field, self ventilated,  
open protected type synchronous generator  
armature Connection  
phase  
Series  
Single-Phase 3-Wire  
22 kW (27.5 kVA)  
20 kW (25.0 kVA)  
120/240V  
standby output  
prime output  
voltage  
Frequency  
60 Hz  
speed  
1800 rpm  
power Factor  
aux. aC power  
1.0  
Single Phase, 60 Hz  
sound level db (a) full load  
at 23 ft. (7 meters)  
63  
weight (no Fuel)  
weight (Fuel)  
1,412 lbs. (640 kg.)  
2,012 lbs. (913 kg.)  
Table 2. engine specifications  
Model  
Type  
ISUZU BV-4LE2 Tier 4i  
4 cycle, water-cooled, direct injection, turbo-charged  
4 cylinders  
no. of Cylinders  
Bore x stroke  
Displacement  
rated output  
starting  
3.34 in. x 3.77 in. (85 mm x 96 mm)  
133 cu. in. (2,179 cc)  
34.3 HP/1800 RPM  
Electric  
Coolant Capacity  
lube oil Capacity  
Fuel Type  
1.74 gal. (6.6 liters)  
2.25 gal. (8.5 liters)  
#2 Diesel Fuel, Low Sulfur Diesel Fuel Only  
100 gal. (379 liters)  
Fuel Tank Capacity  
1.66 gal. (6.3 L)/hr at full load  
0.85 gal. (3.2 L)/hr at 1/2 load  
1.21 gal. (4.6 L)/hr at 3/4 load  
0.58 gal. (2.2 L)/hr at 1/4 load  
Fuel Consumption  
Battery  
12V 53Ah x 1  
page 12 — DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13)  
Download from Www.Somanuals.com. All Manuals Search And Download.  
diMensiOns  
B
C
D
TOP VIEW  
E
A
20  
SIDE VIEW  
F
FRONT VIEW  
Figure 1. Dimensions  
Denyo  
G
Table 3. Dimensions  
reference  
letter  
Dimension in. (mm)  
reference letter  
Dimension in. (mm)  
A
B
C
D
21.06 in. (535 mm.)  
21.06 in. (535 mm.)  
24.21 in. (615 mm.)  
26.38 in. (670 mm.)  
F
G
H
72.83 in. (1,850 mm.)  
39.37 in. (1,000 mm.)  
29.53 in. (750 mm.)  
H
E
25.00 in. (635 mm.)  
DCa20spxu2 (wiTh MlT20 series) • operaTion anD parTs Manual rev. #0 (01/18/13) — page 13  
Download from Www.Somanuals.com. All Manuals Search And Download.