Multiquip Portable Generator DCA10SPX3 User Manual

OPERATION AND PARTS MANUAL  
®
MODEL DCA10SPX3  
60 Hz GENERATOR  
(KUBOTA D1403 DIESEL ENGINE)  
Revision #2 (01/17/11)  
To find the latest revision of this  
publication, visit our website at:  
www.multiquip.com  
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.  
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PAGE 2 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)  
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HERE'S HOW TO GET HELP  
PLEASE HAVE THE MODEL AND SERIAL NUMBER  
ON-HAND WHEN CALLING  
PARTS DEPARTMENT  
800/427-1244 or 310/537-3700  
FAX: 800/672-7877 or 310/637-3284  
SERVICE DEPARTMENT  
800/835-2551 or 310/537-3700  
FAX: 310/638-8046  
WARRANTY DEPARTMENT  
800/835-2551 or 310/537-3700  
FAX: 310/638-8046  
MAIN  
800/421-1244 or 310/537-3700  
FAX: 310/537-3927  
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 3  
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TABLE OF CONTENTS  
Here's How To Get Help .......................................... 3  
Table Of Contents ................................................... 4  
Parts Ordering Procedures ..................................... 5  
Rules For Safe Operation .................................... 6-9  
Towing Safety ........................................................ 10  
Trailer Safety Guidelines .................................. 11-15  
Trailer Wiring Diagram........................................... 16  
Operation and Safety Decals ........................... 17-18  
Specifications ........................................................ 19  
General Information .............................................. 20  
Major Components ............................................... 21  
Dimensions ...................................................... 22-23  
Controls and Indicators .................................... 24-25  
Output Terminals .............................................. 26-27  
Installation ........................................................ 28-29  
Pre-Setup ......................................................... 30-33  
Load Application ................................................... 34  
Start up Procedure .......................................... 35-36  
Shut down Procedure ........................................... 37  
Maintenance .................................................... 38-39  
Generator Wiring Diagram .................................... 40  
Engine Wiring Diagram ......................................... 41  
Troubleshooting (Engine)................................. 42-43  
Troubleshooting (Generator) ................................ 44  
Explanation Of Codes In Remarks Column .......... 46  
Suggested Spare Parts ......................................... 47  
Kubota D1403 Engine  
Crankcase Assembly ....................................... 68-69  
Oil Pan Assembly ............................................. 70-71  
Cylinder Head Assembly .................................. 72-73  
Gear Case Assembly ....................................... 74-75  
Main Bearing Case Assembly .......................... 76-77  
Inlet Manifold Assembly ................................... 78-79  
Exhaust Manifold Assembly ............................. 80-81  
Valve and Rocker Assembly ............................ 82-83  
Head Cover Assembly ..................................... 84-85  
Camshaft Assembly ......................................... 86-87  
Piston and Camshaft Assembly ....................... 88-89  
Flywheel Assembly .......................................... 90-91  
Starter Assembly ............................................. 92-93  
Starter Components Assembly ........................ 94-95  
Injection Pump 1 Assembly.............................. 96-97  
Injection Pump 1 Assembly.............................. 98-99  
Fuel Camshaft Assembly ............................. 100-101  
Governor Assembly ..................................... 102-103  
Speed Control Plate Assembly .................... 104-105  
Engine Stop Lever Assembly ....................... 106-107  
Stop Solenoid Assembly .............................. 108-109  
Alternator Assembly ..................................... 110-111  
Alternator Components Assembly ............... 112-113  
Fan Assembly............................................... 114-115  
Water Flange and Thermostat Assembly..... 116-117  
Water Pump Assembly ................................. 118-119  
Radiator Assembly ....................................... 120-121  
Fuel Filter Assembly .................................... 122-123  
DCA-10SPX3  
AC Generator  
Generator Assembly ........................................ 48-49  
Control Panel Assembly ................................... 50-51  
Output Terminal Assembly ............................... 52-53  
Engine and Radiator Assembly........................ 54-55  
Battery Assembly ............................................. 56-57  
Muffler Assembly ............................................. 58-59  
Fuel Filter Assembly ........................................ 60-61  
Enclosure Assembly......................................... 62-63  
Rubber Seal Assembly..................................... 64-65  
Decal Assembly ............................................... 66-67  
Terms and Condition of Sale-Parts ..................... 124  
NOTE  
Specification and part number  
are subject to change without  
notice.  
PAGE 4 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)  
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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.  
View Parts Diagrams  
Order Parts  
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.*  
Goto www.multiquip.com and click on  
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:  
Dealer Account Number  
Specify Preferred Method of Shipment:  
Dealer Name and Address  
UPS/Fed Ex  
DHL  
Truck  
Priority One  
Ground  
Shipping Address (if different than billing address)  
Return Fax Number  
Next Day  
Second/Third Day  
Applicable Model Number  
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!  
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 5  
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RULES FOR SAFE OPERATION  
NEVER touch the hot exhaust manifold,  
muffler or cylinder. Allow these parts to  
cool before servicing engine or  
generator.  
CAUTION:  
Failure to follow instructions in this manual  
may lead to serious injury or even death!  
This equipment is to be operated by trained  
and qualified personnel only! This  
equipment is for industrial use only.  
The following safety guidelines should always be used when  
operating the DCA-10SPX3 portable generator:  
HighTemperatures – Allow the engine to cool before adding  
fuel or performing service and maintenance functions. Contact  
with hot components can cause serious burns.  
GENERAL SAFETY  
DONOToperateorservicethisequipmentbefore  
readingthisentiremanual.  
The engine of this generator requires an adequate free flow  
of cooling air. Never operate the generator in any enclosed or  
narrow area where free flow of the air is restricted. If the air  
flow is restricted it will cause  
This equipment should not be operated by persons under 18  
years of age.  
serious damage to the  
generator or engine and may  
cause injury to people. The  
generator engine gives off  
DEADLY carbon monoxide  
gas.  
NEVER operate this equipment without proper  
protective clothing, shatterproof glasses,  
steel-toed boots and other protective devices  
required by the job.  
NEVER operate this equipment when not  
feeling well due to fatigue, illness or  
taking medicine.  
CAUTION:  
Always refuel in a well-ventilated area, away  
from sparks and open flames.  
NEVER operate this equipment under  
the influence or drugs or alcohol.  
Always use extreme caution when working with flammable  
liquids. When refueling, stop the engine and allow it to cool.  
DO NOT smoke around or near the  
machine. Fire or explosion could result  
from fuel vapors, or if fuel is spilled on a  
hot engine.  
NEVER use accessories or attachments, which are not  
recommended by MQ Power for this equipment. Damage to  
the equipment and/or injury to user may result.  
NEVER operate the generator in an  
Manufacture does not assume responsibility for any accident  
due to equipment modifications.  
explosive atmosphere or near  
combustible materials. An explosion or  
fire could result causing severe bodily  
harm or even death.  
Whenever necessary, replace nameplate, operation and  
safety decals when they become difficult read.  
Always check the machine for loosened threads or bolts before  
starting.  
Topping-off to filler port is dangerous, as it tends to spill fuel.  
PAGE 6 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)  
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RULES FOR SAFE OPERATION  
CAUTION:  
CAUTION:  
DO NOT touch or open any of the below  
mentioned components while the generator  
is running. Always allow sufficient time for  
the engine and generator to cool before  
performing maintenance.  
Radiator  
1. Radiator Cap - Removing the radiator cap while the  
engine is hot will result in high pressurized, boiling water  
to gush out of the radiator, therefore causing severe  
scalding to any persons in the general area of the  
generator.  
NEVER touch output terminals during operation. This is  
extremely dangerous. Always stop the machine when contact  
with the output terminals is required.  
CAUTION:  
Backfeed to a utility system can cause electrocution  
and/or property damage. Do not connect to any  
building's electrical system except through an approved  
device or after building main switch is opened.  
2. Coolant Drain Plug - Removing the coolant drain plug  
while the engine is hot will result in hot coolant to gush  
out of the coolant drain plug, therefore causing severe  
scalding to any persons in the general area of the  
generator.  
CAUTION:  
3. Engine Oil Drain Plug - Removing the engine oil drain  
plug while the engine is hot will result in hot oil to gush  
out of the oil drain plug, therefore causing severe  
scalding to any persons in the general area of the  
generator.  
Never use damaged or worn cables when connecting power  
tools or equipment to the generator. Make sure power  
connecting cables are securely connected to the generator's  
output terminals, insufficient tightening of the terminal  
connections may cause damage to the generator and  
electrical shock.  
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 7  
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RULES FOR SAFE OPERATION  
NEVER Run engine without air filter. Severe engine damage  
Battery  
may occur.  
CAUTION:  
Always service air cleaner frequently to prevent carburetor  
malfunction.  
Never over fill the battery with water above  
the upper limit.  
Always disconnect the battery before performing service on  
the generator.  
Always be sure the operator is familiar with proper safety  
precautions and operations techniques before using generator.  
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.  
The battery has acids that can cause injury to the eyes and skin.  
To avoid eye irritation, always wear safety glasses. Use well  
insulated gloves when picking up the battery.Use the following  
guidelines when handling the battery:  
DO NOT leave the generator running in the manual mode  
unattended.  
DO NOT allow unauthorized people to operate this  
equipment.  
Always read, understand, and follow procedures in Operator’s  
Manual before attempting to operate equipment.  
Always be sure the operator is familiar with proper safety  
precautions and operations techniques before using generator.  
Refer to the Kubota Engine Owner's Manual for engine  
technical questions or information.  
Loading and Unloading (Crane)  
1. DO NOT drop the battery.There is the possibility of risk  
the battery may explode.  
Before lifting, make sure the generator's lifting hook is secure  
and that there is no apparent damage to the generator itself  
(loose screws, nuts and bolts). If any part is loose or damaged,  
please take corrective action before lifting.  
2. DO NOT expose the battery to open flames, sparks,  
cigarettes etc. The battery contains combustible gases  
and liquids. If these gases and liquids come in contact  
with a flame or spark, an explosion could occur.  
Always drain fuel prior to lifting.  
Always make sure crane or lifting device has been properly  
secured to the hook of guard frame on generator.  
3. Always keep the battery charged. If the battery is not  
charged, a buildup of combustible gas will occur.  
NEVER lift the machine while the engine is running.  
4. Always keep battery charging and booster cables in good  
working condition. Repair or replace all worn cables.  
Use adequate lifting cable (wire or rope) of sufficient strength.  
When lifting the generator, always use the balanced center-  
point suspension hook and lift straight upwards.  
5. Always recharge the battery in an open air environment,  
to avoid risk of a dangerous concentration of combustible  
gases.  
NEVER allow any person or animal to stand underneath the  
machine while lifting.  
6. In case the battery liquid (dilute sulfuric acid) comes in  
contact with clothing or skin, rinse skin or clothing  
immediately with plenty of water.  
When loading the generator on a truck, be sure to use the  
front and back frame bars as a means to secure the generator  
during transport.  
7. In case the battery liquid (dilute sulfuric acid) comes in  
contact with your eyes, rinse eyes immediately with  
plenty of water, then contact the nearest doctor or  
hospital, and seek medical attention.  
PAGE 8 — DCA-10SPX3 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (01/17/11)  
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RULES FOR SAFE OPERATION  
Transporting  
Maintenance Safety  
Always shutdown engine before transporting.  
NEVER lubricate components or attempt service on a  
running machine.  
Tighten fuel tank cap securely.  
Always allow the machine a proper amount of time to cool  
before servicing.  
Drain fuel when transporting generator over long distances  
or bad roads.  
Keep the machinery in proper running condition.  
Always tie-down the generator during transportation by  
securing the generator.  
Fix damage to the machine immediately and always replace  
broken parts.  
If generator is mounted on a trailer, make sure trailer complies  
with all local and state safety transportation laws. See page  
10 for basic towing procedures.  
Dispose of hazardous waste properly. Examples of  
potentially hazardous waste are used motor oil, fuel,  
coolant and fuel filters.  
Emergencies  
DO NOT use plastic containers to dispose of hazardous  
Always know the location of the nearest fire extinguisher  
and first aid kit. Know the location of the nearest telephone.  
Also know the phone numbers of the nearest ambulance,  
doctor and fire department.  
waste.  
DO NOT pour waste, oil, coolant or fuel directly onto the  
ground, down a drain or into any water source.  
DCA-10SPX3 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (01/17/11) — PAGE 9  
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