MULTIQUIP Power WHISPERWATT DCA-36SPX, Operation And Parts Manual

Page 1: ...OPERATION MANUAL OPERATION AND PARTS MANUAL Revision 1 04 14 10 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES WHISPERWATTTM SERIES MODEL DCA 36SPX 60 Hz GENERATOR PARTS LIST NO B2871300404 S N...

Page 2: ...PAGE 2 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 Diesel engine exhaust and some of PROPOSITION 65WARNING...

Page 3: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 3 1 NOTE PAGE...

Page 4: ...tputTerminal Panel Familiarization 26 28 Load Application 29 GaugeReading 30 Pre Setup 31 34 Generator Start up Procedure Manual 35 36 Generator Start up Procedure Auto Mode 37 Generator Shut Down Pro...

Page 5: ...ite N View Parts Diagrams N Order Parts N Print Specification Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and q...

Page 6: ...i f i c e p S e n i g n E 2 e l b a T l e d o M T 1 G J 4 B B U Z U Z I e p y T d e g r a h c o b r u t n o i t c e j n i t c e r i d d e l o o c r e t a w e l c y C 4 s r e d n i l y C f o o N s r e...

Page 7: ...D TOP VIEW SIDE VIEW 36 S N O I S N E M I D 3 E L B A T e c n e r e f e R r e t t e L m m t f n o i s n e m i D 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 8 3 7 n i 1 9 2 F m m 0 0...

Page 8: ...ERIOUSLY 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 gas...

Page 9: ...nd clothing 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 appli...

Page 10: ...ident 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...

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

Page 12: ...ery 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 con...

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: ...ake sure 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 followe...

Page 15: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 15 1 NOTE PAGE...

Page 16: ...igures 2 and 3 These decals are provided for operator safety and maintenance information The illustration below and on the preceding page show the decals as they appear on the machine Should any of th...

Page 17: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 17 1 DCA 36SPX GENERATOR DECALS Figure 3 Generator Decals Cont inued...

Page 18: ...PAGE 18 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 Figure 4 Typical Generator Grounding Application DCA 36SPX INSTALLATION...

Page 19: ...m2 or larger b Aluminum 8 AWG 8 4 mm2 or larger 2 When grounding the generator Figure 4 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect...

Page 20: ...Duringsteadystateloads 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 r...

Page 21: ...b m e s s A r e l f f u M 4 y l b m e s s A r e t l i F r i A 5 y l b m e s s A y r e t t a B 6 y l b m e s s A r o t a r e n e G 7 y l b m e s s A e n i g n E 8 y l b m e s s A k n a T l e u F 9 y l...

Page 22: ...PAGE 22 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 NOTE PAGE...

Page 23: ...or output in any fashion it is for current reading only 6 Main Circuit Breaker This three pole 150A main breaker is provided to protect the the U O andV Output Terminal Lugs from overload Located behi...

Page 24: ...PAGE 24 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 Figure 7 Engine Operating Panel DCA 36SPX ENGINE OPERATING PANEL...

Page 25: ...automatic transfer switch ATS will start the generator automatically via the generator s auto start contacts connected to the ATS s start contacts Please refer to your ATS installation manual for furt...

Page 26: ...8 shownbelowislocated ontheright handside leftfromcontrolpanel ofthegenerator Lift up on the cover to gain access to receptacles and terminal lugs Figure 8 OutputTerminal Panel DCA 36SPX OUTPUT TERMIN...

Page 27: ...dependent on the load requirements of the OutputTerminal Lugs Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Turning the knob clockwise will incre...

Page 28: ...sure to switch ALL circuit breakers to the OFF position prior to starting the engine DCA 36SPX OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current Relay An over current relay Figure 14 is connected to...

Page 29: ...load 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 electrici...

Page 30: ...Read the OutputTerminal Gauges The gauges on the control panel are provided to help observe how much power is being supplied at the Output terminals lugs Figure 16 AC Ammeter Amp reading on U lug Figu...

Page 31: ...ough the filler hole but DO NOT overfill Make sure the generator is level and verify that the oil level is maintained between the two notches Figure 20 on the dipstick See Table 8 for proper selection...

Page 32: ...e fuel cap internal fuel tank and fill fuel tank as shown Figure 23 ALWAYS place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped in...

Page 33: ...the negative battery terminal disconnected Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the ISUZU Engine Owner s Manual Fan BeltTension A slack fan belt may con...

Page 34: ...mps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator will occur Pay close at...

Page 35: ...heengine Figure 28 Main Aux and GFCI Circuit Breakers OFF 3 Connect the load to the receptacles or the output terminallugsasshowninFigure8 Theseloadconnection points can be found on the output termina...

Page 36: ...rmaloperatingconditions this speed is approximately 1800 RPM s 9 The coolanttemperaturegauge Figure 37 will indicate the coolant temperature Under normal operating conditions the coolant temperature s...

Page 37: ...electrical system a licensed electrician must install an isolation transfer switch Serious damage to the building s electrical system may occur without this transfer switch DANGER ELECTRICAL SYSTEM H...

Page 38: ...Control Switch Off Reset 4 Verify that the all status LED on the MPEC display are OFF not lit 5 Remove all loads from the generator 6 Inspect entire generator for any damage or loosening of component...

Page 39: ...fter 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 E...

Page 40: ...r disassembling the fuel system bleed the system according to the following procedure See the VOLVOEngine Manual for details To restart after running out of fuel turn the switch to the ON position for...

Page 41: ...LY function when commercial power has been supplied to them Figure 43 To apply commercial power to these receptacles a power cord of adequate size will be required SeeTable 6 When using the generator...

Page 42: ...e trailer so the brake lights and turn signals can be connected to the towing vehicle 16 Application Indicates which units can be employed on a particular trailer Trailer Maintenance This section is i...

Page 43: ...rgebrakingrequirestheinstallationofanactuator 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 v...

Page 44: ...loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 14 Figure 45 Major Suspension Components DCA 36SPX TRAILER MAINTENANCE DO NO...

Page 45: ...the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence see Figure 46 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes...

Page 46: ...PAGE 46 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX TRAILERWIRING DIAGRAM Figure 47 Trailer Towing Vehicle Wiring Diagram...

Page 47: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 47 1 DCA 36SPX GENERATORWIRING DIAGRAM Figure 48 GeneratorWiring Diagram...

Page 48: ...PAGE 48 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENGINEWIRINGDIAGRAM Figure 49 Engine Wiring Diagram...

Page 49: ...l z z 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...

Page 50: ...r o 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...

Page 51: ...t o 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...

Page 52: ...g i H n o s i t h g i l t c e r r o c n i n o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r...

Page 53: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 53 1 NOTE PAGE...

Page 54: ...t guarantee the availability of the parts listed NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order QTY Col...

Page 55: ...10501003 HOSE RADIATOR UPPER 1 M1310501103 HOSE RADIATOR LOWER 1 0602011053 RADIATOR CAP 1 0605505070 FUEL CAP 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNIT WATERTEMPERATURE 6 8953692993 FILTER FUE...

Page 56: ...PAGE 56 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX GENERATOR ASSY GENERATOR ASSY...

Page 57: ...17 0071906310 BEARING 1 2 B3164400203 COUPLING RING 1 3 0012108030 HEX HEAD BOLT 6 4 8081340603 STATOR ASSY 1 4 1 0845041904 GROMMET 1 4 2 0845031404 GROMMET 1 5 B3164600003 COUPLING ADAPTER 1 6 00121...

Page 58: ...PAGE 58 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY...

Page 59: ...9988N 1 2 0601831340 SWITCH 1 3 0602120095 TACHOMETER 1 4 0602122093 OIL PRESSURE GAUGE 1 5 0602123090 WATERTEMPERATUR GAUGE 1 6 0602121080 CHARGING AMMETER 1 7 0602125090 FUEL GAUGE 1 8 0602103092 A...

Page 60: ...PAGE 60 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX CONTROL BOX ASSY CONTROL BOX ASSY S N 7800001 7800129...

Page 61: ...ET 1 REPLACES 0601823109 13 0027104020 MACHINE SCREW 2 14 M1223000503 CONTROL PANEL 1 15 0601807641 FREQUENCY METER 45 65 HZ 240V 1 16 0601806845 AC AMMETER 0 200A 5A 1 17 0601801040 AMMETER CHANGE OV...

Page 62: ...PAGE 62 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY...

Page 63: ...HOSE LOWER 1 10 0605515147 HOSE BAND 4 11 M1310300903 FAN SHROUD 1 12 0016908020 HEX HEAD BOLT 4 13 M1310300504 FAN GUARD 1 14 M1310300604 FAN GUARD 1 15 0016908020 HEX HEAD BOLT 6 16 0602046275 AIR C...

Page 64: ...PAGE 64 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENGINE AND RADIATOR ASSY ENGINE RADIATOR ASSY...

Page 65: ...HOSE BAND 2 47 0602220910 CLAMP 2 48 0016908020 HEX HEAD BOLT 2 49 0199800700 DRAIN HOSE 1 50 0269200850 BLOWBY HOSE 1 51 0605515198 HOSE BAND 2 52 RCT 2010 CLAMP 1 53 0016908020 HEX HEAD BOLT 1 54 0...

Page 66: ...PAGE 66 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY...

Page 67: ...UT 4 13 0016906020 HEX HEAD BOLT 2 14 0016906016 HEX HEAD BOLT 4 15 8085183004 CABLE OUTLET COVER 1 16 8085182004 CABLE OUTLET COVER SUPPORTER 1 17 0016906020 HEX HEAD BOLT 6 18 0601870440 CIRCUIT BRE...

Page 68: ...PAGE 68 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX BATTERY ASSY BATTERY ASSY...

Page 69: ...REMARKS 1 0602220187 BATTERY 1 2 B9310500004 BATTERY SHEET 1 3 M9103000304 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 INCLUDES ITEM W 5 0040006000 WASHER LOCK 2 6 M1346200004 BATTERY CABLE 1 7 M1...

Page 70: ...PAGE 70 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX MUFFLER ASSY MUFFLER ASSY...

Page 71: ...Y REMARKS 1 B3923200044 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M1333002503 EXHAUST PIPE 1 4 8943690210 GASKET 1 REPLACES P N 0602320101 5 B3333200104 GASKET 1 6 0039308000 HEX HEAD NUT 6 7 001690803...

Page 72: ...PAGE 72 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX FUELTANK ASSY FUEL TANK ASSY...

Page 73: ...7 1 0222100085 RUBBER SHEET 2 8 1502025103 DRAIN JOINT 1 9 0802011104 DRAIN BOLT 1 10 0150000018 O RING 1 11 0016906020 HEX HEAD BOLT 2 12 M1363400104 DRAIN HOSE 1 13 0605515064 HOSE BAND 2 14 8943672...

Page 74: ...PAGE 74 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENCLOSURE ASSY ENCLOSURE ASSY...

Page 75: ...30 HEX HEAD BOLT 8 13A 0040014000 WASHER LOCK 8 13B 0041214000 WASHER FLAT 8 14 B2444000302 REAR FRAME 1 14A M1493300504 ACOUSTIC SHEET 1 15 0016908020 HEX HEAD BOLT 4 16 B2444300603 REAR COVER 1 17 B...

Page 76: ...PAGE 76 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX ENCLOSURE ASSY CONT ENCLOSURE ASSY CONT...

Page 77: ...1453301104 DUCT 2 40A M1493405504 ACOUSTIC SHEET 2 41 B3454300804 DUCT 1 41A M1493407904 ACOUSTIC SHEET 1 42 0207006000 HEX HEAD NUT 15 43 B9114000002 DOOR HANDLE ASSY 3 44 0021806016 MACHINE SCREW 12...

Page 78: ...PAGE 78 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX RUBBER SEALS ASSY RUBBER SEALS ASSY...

Page 79: ...70 RUBBER SEAL 3 5 M1490300104 RUBBER SEAL 1 6 0228800515 RUBBER SEAL 1 7 0228900485 RUBBER SEAL 1 8 0228900910 RUBBER SEAL 1 9 0229200900 RUBBER SEAL 2 10 0229200840 RUBBER SEAL 1 11 0228800770 RUBBE...

Page 80: ...PAGE 80 DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 DCA 36SPX NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSY...

Page 81: ...L DIESEL FUEL 1 S 1756 13 6360620004 DECAL FUEL DRAIN PLUG 1 S 1883 14 B9505000505 DECAL WARNING 2 B90400040 15 1320610603 DECAL WATER OIL CHECK 1 S 176016 16 B9504100104 DECAL WARNING 1 B90420000 17...

Page 82: ...aper products g Items purchased in kits h The sender will be notified of any material 7 received that is not acceptable Such material will be held for five 8 working days from notification pending ins...

Page 83: ...DCA 36SPX OPERATION AND PARTS MANUAL REV 1 04 14 10 PAGE 83 1 NOTE PAGE...

Page 84: ...erences and technical data contained 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 in...