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operation manual DCA-20SPX - INSTALLATION, Typical Generator Grounding Application
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DCA-20SPX
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Troubleshooting
Specification
Install
Parts list
DCA-20SPX -TRAILERWIRING DIAGRAM
Warranty
Dimension
Maintenance
Connecting Loads
Symptom
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Image 18
DCA-20SPX
— INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 18 —
DCA-20SPX—
OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)
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Contents
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES
PARTS LIST NO. B1871302604
OPERATION AND PARTS MANUAL
MODEL DCA-20SPX
PROPOSITION 65WARNING
Diesel engine exhaust and some of
PAGE 2 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
NOTE PAGE
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
COMPONENT DRAWINGS
TABLE OF CONTENTS
Specification and part
NOTEnumber are subject to change without notice
Ordering parts has never been easier
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Choose from three easy options
Table 2. Engine Specifications
DCA-20SPX - SPECIFICATIONS
Table 1. Generator Specifications
PAGE 6 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
TABLE 3. DIMENSIONS
DCA-20SPX - DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
Dimension ft. mm
SAFETY MESSAGE ALERT SYMBOLS
DCA-20SPX - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
Whisperwatt Generator
CAUTION - ACCIDENTAL STARTING
DCA-20SPX - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - OVER-SPEED CONDITIONS
General Safety
DCA-20SPX - RULES FOR SAFE OPERATION
DANGER - READTHIS MANUAL
Grounding Safety
Maintenance Safety
Power Cord Safety
DCA-20SPX - RULES FOR SAFE OPERATION
DANGER - EXPLOSION HAZARDS
Battery Safety
DCA-20SPX - RULES FOR SAFE OPERATION
WARNING - BURN HAZARDS
DCA-20SPX - RULES FOR SAFE OPERATION
DANGER-Electrocution Hazards
DANGER-Lethal Exhaust Gas Hazards
DANGER
Towing and Transporting Safety
DCA-20SPX - RULES FOR SAFE OPERATION
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NOTE PAGE
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
DCA-20SPX - GENERATOR DECALS
Figure 2. Generator Decals
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DCA-20SPX - GENERATOR DECALS
Figure 3. Generator Decals Cont inued
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
DCA-20SPX - INSTALLATION
Figure 4.Typical Generator Grounding Application
PAGE 18 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
Indoor Installation
DCA-20SPX - INSTALLATION
Outdoor Installation
CAUTION - EXHAUST HAZARD
Engine Operating Panel
DCA-20SPX - GENERAL INFORMATION
Generator
Generator Control Panel
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
DCA-20SPX - MAJOR COMPONENTS
Figure 5. Major Components
Table 4. Generator Major Components
NOTE PAGE
PAGE 22 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX - GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
AUTO MANUAL OFF/RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE
DCA-20SPX - ENGINE OPERATING PANEL
Figure 7. Engine Operating Panel
PAGE 24 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX - ENGINE OPERATING PANEL
9. Auto On/Off Engine Controller MPEC
Figure 8. Output Terminal Panel
DCA-20SPX - OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
Figure 11. Voltage Regulator Control Knob
DCA-20SPX - OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Figure 9. G.F.C.I. Receptacle
Over Current Relay
Connecting Loads
Figure 14. Over Current Relay Figure 13. Connecting Loads
DCA-20SPX - OUTPUT TERMINAL PANEL FAMILIARIZATION
DCA-20SPX - LOAD APPLICATION/MAXIMUM AMPERAGE
Single Phase Load
Table 5. Power Factor By Load
DANGER - ELECTRICAL SYSTEM HAZARDS
Figure 19. Output Terminal Lugs 120 Single Phase Connections
How to Read the Output Terminal Gauges
Figure 17. Output Terminal Lugs 240 Single Phase Connections
DCA-20SPX - GAUGE READING/TERMINAL PANEL CONNECTIONS
Lubrication Oil
DCA-20SPX - SETUP
Circuit Breakers
Fuel Check
WARNING - RESPIRATORY HAZARDS
DCA-20SPX - SETUP
Refueling Procedure
Figures 24 and
Air Cleaner
Cleaning the Radiator
Table 10. Anti-Freeze Operating Temperatures
Coolant Antifreeze/Summer Coolant/Water
Figure 27. Battery Connections
Battery
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
Figure 30. MPEC Control Switch Manual Position
DCA-20SPX - GENERATOR START-UP PROCEDURE MANUAL
Manual Start-up Procedure
Before Starting
Figure 33. Voltmeter
Figure 37. Coolant Temperature Gauge
Figure 34. Voltage Adjust Control Knob
Figure 38. Engine Tachometer Gauge
Figure 41. MPEC Control Switch AUTO
DCA-20SPX - GENERATOR START-UP PROCEDURE AUTO MODE
CAUTION - BACKUP GENERATOR USE
WARNING - AUTO MODE MAINTENANCE
Emergency Shutdown Procedure
DCA-20SPX - GENERATOR SHUT-DOWN PROCEDURES
Normal Shutdown Procedure
Figure 42. MPEC Control Switch Off/Reset
Service Daily
DCA-20SPX - MAINTENANCE
Air Cleaner with Dust Indicator
General Inspection
Check Oil Level
Cleaning the Fuel Strainer
Air Removal
Replacing Oil Filter
DCA-20SPX - MAINTENANCE
Figure 43. Battery Charger JacketWater Heater Power Connections
DCA-20SPX -TRAILER MAINTENANCE
Trailer Maintenance
Brakes
DCA-20SPX -TRAILER MAINTENANCE
Brake Adjustment
Hydraulic Surge Brakes
TireWear/Inflation
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
Suspension
DCA-20SPX -TRAILER MAINTENANCE
Lug Nut Torque Requirements
Figure 46. Wheel Lug Nuts Tightening Sequence
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
DCA-20SPX -TRAILERWIRING DIAGRAM
Figure 47. Trailer/Towing Vehicle Wiring Diagram
PAGE 46 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX - GENERATORWIRING DIAGRAM
Figure 48. Generator Wiring Diagram
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
DCA-20SPX - ENGINEWIRING DIAGRAM
Figure 49. Engine Wiring Diagram
PAGE 48 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
SYMPTOM
DCA-20SPX -TROUBLESHOOTING ENGINE
TABLE 16. ENGINE TROUBLESHOOTING
POSSIBLE PROBLEM
SYMPTOM
DCA-20SPX -TROUBLESHOOTING ENGINE
TABLE 16. ENGINE TROUBLESHOOTING CONTINUED
POSSIBLE PROBLEM
SYMPTOM
DCA-20SPX -TROUBLESHOOTING GENERATOR
TABLE 17. GENERATOR TROUBLESHOOTING
POSSIBLE PROBLEM
SYMPTOM
DCA-20SPX -TROUBLESHOOTING ENGINE CONTROLLER
TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC
POSSIBLE PROBLEM
NOTE PAGE
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
QTY. Column
SAMPLE PARTS LIST
DCA-20SPX - EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
DCA-20SPXWHISPERWATTGENRATOR W/ISUZU AA-4LE2 DIESEL ENGINE
DCA-20SPX - SUGGESTED SPARE PARTS
Description
1TO 3 UNITS
DCA-20SPX - GENERATOR ASSY
GENERATOR ASSY
PAGE 56 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX - GENERATOR ASSY
PART NAME
REMARKS
HEX SOCKET HEAD CAP SCREW
DCA-20SPX- ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
PAGE 58 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
REMARKS
DCA-20SPX- ENGINE OPERATING PANEL ASSY
PART NAME
ECU9988N220V
DCA-20SPX- CONTROL BOX ASSY
CONTROL BOX ASSY. S/N 7800001~7800129
PAGE 60 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
PART NAME
AMMETER CHANGE-OVER SWITCH
DCA-20SPX- CONTROL BOX ASSY
REMARKS
DCA-20SPX- ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
PAGE 62 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
REMARKS
DCA-20SPX- ENGINE AND RADIATOR ASSY
PART NAME
ENGINE, ISUZU AA-4LE2 DA-05
DCA-20SPX- ENGINE AND RADIATOR ASSY
PAGE 64 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- ENGINE AND RADIATOR ASSY
PART NAME
AFTER THE PART NUMBER WHEN ORDERING ANY
DCA-20SPX- OUTPUTTERMINAL ASSY
THE PART NUMBERS LISTED INDICATE DEFAULT COLOR
PAGE 66 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
RECEPTACLE, 250V 50A CS6369
DCA-20SPX- OUTPUTTERMINAL ASSY
PART NAME
OUTPUT TERMINAL ASSY
DCA-20SPX- BATTERY ASSY
BATTERY ASSY
PAGE 68 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- BATTERY ASSY
PART NAME
DCA-20SPX- MUFFLER ASSY
MUFFLER ASSY
PAGE 70 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- MUFFLER ASSY
PART NAME
DCA-20SPX- FUELTANK ASSY
FUEL TANK ASSY
PAGE 72 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- FUELTANK ASSY
PART NAME
REMARKS
AFTER THE PART NUMBER WHEN ORDERING ANY
DCA-20SPX- ENCLOSURE ASSY
THE PART NUMBERS LISTED INDICATE DEFAULT COLOR
PAGE 74 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- ENCLOSURE ASSY
PART NAME
AFTER THE PART NUMBER WHEN ORDERING ANY
DCA-20SPX- ENCLOSURE ASSY. CONT
THE PART NUMBERS LISTED INDICATE DEFAULT COLOR
PAGE 76 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- ENCLOSURE ASSY. CONT
PART NAME
ENCLOSURE ASSY. CONT
DCA-20SPX- RUBBER SEALS ASSY
RUBBER SEALS ASSY
PAGE 78 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- RUBBER SEALS ASSY
PART NAME
RUBBER SEALS ASSY
DCA-20SPX- NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
PAGE 80 - DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10
DCA-20SPX- NAMEPLATE AND DECALS ASSY
PART NAME
REMARKS
PAYMENT TERMS
EffectiveFebruary 22, 2006 TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
NOTE PAGE
DCA-20SPX- OPERATION AND PARTS MANUAL - REV. #2 04/14/10 - PAGE
Carson, CA
Contact mqpower@multiquip.com
18910 Wilmington Ave
Contact mq@multiquip.com