Multiquip Whisperwatt Series Dca 20Spx Users Manual Rev 2

WHISPERWATT SERIES DCA-20SPX Generators_portable_whisperwatt_DCA20SPX_rev_2_manual_DataId_19093_Version_1

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2015-02-09

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Revision #2 (04/14/10)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

WHISPERWATTTM SERIES

MODEL DCA-20SPX

60 Hz GENERATOR

PARTS LIST NO. B1871302604

PAGE 2 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Diesel engine exhaust and some of

PROPOSITION 65 WARNING

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 3

NOTE PAGE

PAGE 4 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

TABLE OF CONTENTS

Specification and part

number are subject to

change without notice.

NOTE

MQ POWER DCA-20SPXMQ POWER DCA-20SPX

MQ POWER DCA-20SPX

WHISPERWHISPER

WHISPERWW

WAA

ATTTT

TTTT

TTTMTM

TMTM

GENERATORGENERATOR

GENERATOR

California Proposition 65 Warning ..................................... 2

Table Of Contents ............................................................. 4

Parts Ordering Procedures ............................................... 5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-15

Generator Decals....................................................... 16-17

Installation ................................................................. 18-19

General Information ........................................................ 20

Major Components ......................................................... 21

Generator Control Panel ................................................. 23

Engine Operating Panel ............................................. 24-25

Output Terminal Panel Familiarization ........................ 26-28

Load Application ............................................................. 29

Gauge Reading ............................................................... 30

Pre-Setup .................................................................. 31-34

Generator Start-up Procedure (Manual) ..................... 35-36

Generator Start-up Procedure (Auto Mode) .................... 37

Generator Shut-Down Procedure .................................... 38

Maintenance (Engine) ................................................ 39-41

Maintenance (Trailer) ................................................. 42-45

Trailer Wiring Diagram ..................................................... 46

Generator Wiring Diagram ............................................... 47

Engine Wiring Diagram ................................................... 48

Troubleshooting (Engine) ........................................... 49-50

Troubleshooting (Generator) ............................................ 51

Engine Controller Troubleshooting ................................... 52

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

Generator Assembly .................................................. 56-57

Engine Operating Panel Assembly ............................ 58-59

Control Box Assembly ............................................... 60-61

Engine and Radiator Assembly ................................. 62-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure Assembly ................................................. 74-77

Rubber Seals Assembly ............................................ 78-79

Nameplate and Decals .............................................. 80-81

Terms and Condition of Sale — Parts ............................ 84

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 5

PARTS ORDERING PROCEDURES

www.mqpower.com

Ordering parts has never been easier!

Choose from three easy options:

WE ACCEPT ALL MAJOR CREDIT CARDS!

When ordering parts, please supply:

R Dealer Account Number

R Dealer Name and Address

R Shipping Address (if different than billing address)

R Return Fax Number

R Applicable Model Number

R Quantity, Part Number and Description of Each Part

R Specify Preferred Method of Shipment:

UPS/Fed Ex DHL

N Priority One Truck 

N Ground

N Next Day

N Second/Third Day

If you have an MQ Account, to obtain a Username

and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact you

District Sales Manager for more information.

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

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 qualify for a 5% 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)

Fax your order in and qualify for a 2% Discount

on Standard orders for all orders which include

complete part numbers.*

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

Best Deal!

International Customers should contact

their local Multiquip Representatives for

Parts Ordering information.

Non-Dealer Customers:

Contact your local Multiquip Dealer for

parts or call 800-427-1244 for help in

locating a dealer near you.

Note: Discounts Are Subject To Change

Effective:

January 1st, 2006

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

PAGE 6 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — SPECIFICATIONS

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DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 7

DCA-20SPX — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

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PAGE 8 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

This Owner's Manual has been

developed to provide complete

instructions for the safe and

efficient operation of the

MQ Power

Model DCA-20SPX

Whisperwatt™ Generator.

Before using this generator, ensure that the operating

individual has read and understands all instructions in

this 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.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! HAZARD SYMBOLS

Potential hazards associated with the operation of this

equipment will be referenced with "

Hazard Symbols

" which

appear throughout this manual, and will be referenced in

conjunction with Safety "

Message Alert Symbols

NOTE

DCA-20SPX — SAFETY MESSAGE ALERT SYMBOLS

SAFETY MESSAGE ALERT SYMBOLS

The three (3) 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 three words:

DANGER, WARNING, or CAUTION.

You WILL be KILLED or SERIOUSLY 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 gases contain

poisonous carbon monoxide. This gas is

colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

equipment in a confined area or enclosed structure that

does not provide ample free flow air.

Gasoline

is extremely flammable, and

its vapors can cause an explosion if

ignited. DO NOT start the engine near

spilled fuel or combustible fluids.

DO NOT fill the fuel tank while the engine

is running or hot.

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from

the ignition system. Store fuel in approved containers, in

well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Engine components can generate extreme

heat. To prevent burns, DO NOT touch these

areas while the engine is running or

immediately after operations. NEVER

operate the engine with heat shields or heat

guards removed.

WARNING

DANGER

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, there

exists the possibility of

electrocution,

electrical shock or burn,

which can cause

severe bodily harm

or even

DEATH!

DANGER - ELECTROCUTION HAZARDS

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 9

DCA-20SPX — SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the engine ON/OFF

switch (MPEC) in the OFF/RESET

position when the generator is not in use.

ALWAYS wear approved

respiratory

protection.

ALWAYS wear approved

eye

and

hearing

protection.

Other important messages are provided throughout this

manual to help prevent damage to your generator, other

property, or the surrounding environment.

This generator, other property, or

the surrounding environment

could be damaged if you do not

follow instructions.

NOTE

NEVER tamper with the factory settings

of the engine governor or settings.

Personal injury and damage to the engine

or equipment can result if operating in

speed ranges above maximum allowable.

CAUTION - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,

or guards removed. Keep

fingers

hands

hair

and 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 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 turbocharges, and reduce the operating

performance.

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.

Wet stacking does 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.

CAUTION - ENGINE LOAD (WET-STACKING)

PAGE 10 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — RULES FOR SAFE OPERATION

The following safety guidelines should always be used when

operating the

DCA-20SPX Whisperwatt™ AC Generator.

General Safety:

■

DO NOT operate or service this

equipment before reading this entire

manual.

The operator MUST BE familiar with proper safety

precautions and operations techniques before using

generator.

■

This equipment should not be operated by persons under

18 years of age.

■

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.

■

NEVER operate this equipment under the influence or

drugs or alcohol.

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.

DANGER - READ THIS MANUAL!

■

ALWAYS wear proper respiratory (mask),

hearing and eye protection equipment when

operating the generator.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

Manufacturer does not assume responsibility for any

accident 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

to the equipment and/or injury to user may result.

■

The engine section of this generators 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 serious

damage to the generators

or engine and may cause

injury to people.

Remember the generator's

engine gives off

DEADLY

carbon monoxide gas.

■

NEVER touch the hot exhaust

manifold, muffler or cylinder.

Allow these parts to cool before

servicing engine or generators.

■

ALWAYS refuel in a well-ventilated area, away from sparks

and open flames.

■

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 operate the generator in an

explosive atmosphere or near

combustible materials. An explosion or

fire could result causing severe

bodily

harm or even death.

■

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.

DANGEROUS

GAS FUMES

Denyo

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 11

DCA-20SPX — RULES FOR SAFE OPERATION

■

ALWAYS be sure the operator is familiar with proper safety

precautions and operation techniques before using

generators.

NEVER leave the generator unattended, turn off engine when

unattended.

Unauthorized equipment modifications will void all warranties.

ALWAYS ensure generator is on level ground before use.

DO NOT place hands or fingers inside generators engine

compartment when engine is running.

NEVER run engine without air cleaner. Severe engine damage

may occur.

NEVER change or adjust the engine speed which has been

set at the factory prior to shipping.

Power Cord Safety

NEVER let power cables or cords

lay in wate

NEVER

stand in water

while AC power from the generators

is being transfer to a load.

NEVER use a defective or frayed power cable. Check the

cable for cuts in the insulation.

NEVER use a extension cord that is frayed or damaged where

the insulation has been cut.

ALWAYS make certain that proper power or extension cord

has been selected for the job See Table 4.

Grounding Safety

ALWAYS make sure that electrical circuits are properly

grounded

per the

National Electrical Code

(NEC) and

local codes before operating generator. Severe

injury

death!

by electrocution can result from operating an

ungrounded generator.

ALWAYS make sure the generators are properly grounded to

a suitable earth ground (GROUND ROD). See installation in

this manual.

NEVER use

gas piping

as an electrical ground.

Maintenance Safety

NEVER lubricate components or attempt service on a running

machine.

High Temperatures – Always stop engine and

allow the engine to cool before adding fuel, oil

or performing service and maintenance

functions. Contact with

hot!

components can

cause serious burns.

Keep the machinery in proper running condition.

Fix damage to the machine immediately and replace any

broken parts immediately.

ALWAYS replace any worn or damaged warning decals.

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 un-authorized personnel.

The electrical voltage required to operate the generator can

cause severe injury or even death through physical contact

with live circuits.

Turn all circuit breakers OFF before

performing maintenance on the generator.

Dispose of hazardous waste properly. Examples of potentially

hazardous waste are used motor oil, fuel and fuel filters.

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.

■

ALWAYS allow the machine a proper amount of time to

cool before servicing.

■

ALWAYS service air cleaner frequently to prevent engine

malfunction.

■

ALWAYS disconnect the

NEGATIVE battery terminal

before performing service on the generator.

■

Follow all battery safety guidelines listed in this manual

when handleing or servicing the generator.

PAGE 12 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — RULES FOR SAFE OPERATION

Battery Safety

Use the following guidelines when handling the battery:

■

The battery contains 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.

■■

■

ALWAYS keep the battery charged. If the battery is not

charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good

working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air

environment, to avoid risk of a dangerous concentration

of combustible gases.

In case the battery liquid (dilute sulfuric acid) comes in

contact with

clothing or skin

, rinse skin or clothing

immediately with plenty of water.

In case the battery liquid (dilute sulfuric acid) comes in

contact with your

EYES

, rinse eyes immediately with

plenty of water and contact the nearest doctor or hospital

to seek medical attention.

The risk of an explosion exists when performing service

on the battery. To avoid

severe injury

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 contains combustible gases and liquids.

If these gases and liquids come in contact with a flame

or spark, an explosion could occur.

DANGER - EXPLOSION HAZARDS

To prevent burns, DO NOT touch or open any of the below

mentioned components while the engine is

running or immediately after operations.

Always allow sufficient time for the engine

and generator to cool before performing

maintenance.

■

Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water

to gush out of the radiator, causing severe scalding to

any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the

coolant drain plug while the engine is

hot will result in hot coolant gushing

out of the coolant drain plug, therefore

causing severe scalding to any persons

in the general area of the generator.

■

Engine Oil Drain Plug - Removing the engine oil drain

plug while the engine is hot will result in hot oil gushing

out of the oil drain plug, therefore causing severe

scalding to any persons in the general area of the

generator.

WARNING - BURN HAZARDS

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 13

DCA-20SPX — RULES FOR SAFE OPERATION

Backfeed to a utility system can cause

electrocution

and or property damage.

NEVER connect the generators to a

building's electrical system without a

transfer switch or other approved device.

All installations should be performed by

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!

Emergencies

ALWAYS know the location of the

nearest

fire extinguisher

ALWAYS know the location of the nearest

first aid kit

In emergencies

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.

DANGERDANGER

DANGER

Electrocution HazardsElectrocution Hazards

Electrocution Hazards

During operation of this generation, there

exists the possibility of

electrocution

electrical shock or burn

, which can

cause

severe bodily harm

or even

DEATH!

To avoid these hazards:

NEVER use

damaged

worn

cables when connecting

equipment to the generator. Make sure power connecting

cables are securely connected to the generator’s output

receptacles, incorrect connections 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 place all circuit breakers in the “OFF”

position when contact with the output receptacles is

required. There exist the possibility of

electrocution,

electrical shock or burn, which can cause severe

bodily harm or even death

NEVER grab or touch a live

power cord with wet hands, the

possibility exist of electrical

shock, electrocution, and even

death!

ACCIRCUIT

BREAKER

ACCIRCUIT

BREAKER

OFF

22A

120

20A

120V

OFF

GA-2.9R

2900

DANGER

Using a generator indoors .CAN KILL YOU IN MINUTES

Generator exhaust contains carbon monoxide. This is

a posion you cannot see or smell

NEVER use inside a home

or garage, even if doors

and windows are open

ACCIRCUIT

BREAKER

ACCIRCUIT

BREAKER

OFF

22A

120

20A

120V

OFF

GA-2.9R

2900

ACCIRCUIT

BREAKER

ACCIRCUIT

BREAKER

OFF

22A

120

20A

120V

OFF

GA-2.9R

2900

Only use OUTSIDE and

far away from windows,

doors, and vents.

Avoid other generator hazards.

.READ MANUAL BEFORE USE

Engine exhaust gases contain

poisonous carbon monoxide. This gas

is colorless and odorless, and can

cause death if inhaled. NEVER operate

this equipment in a confined area or

enclosed structure that does not provide

ample free flow air.

DANGERDANGER

DANGER

Lethal Exhaust Gas HazardsLethal Exhaust Gas Hazards

Lethal Exhaust Gas Hazards

PAGE 14 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Check with your local county or state safety towing

regulations, in addition to meeting

Department of

Transportation

(DOT)

Safety Towing Regulations

, before

towing your generator.

CAUTION - FOLLOW TOWING REGULATIONS

■

The maximum speed for highway towing is 55 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 15 MPH or less depending on type of

terrain.

■

Place

chock blocks

underneath wheel to prevent rolling,

while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to

a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding,

or jack-knifing. Smooth, gradual starts and stops will

improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times

when towing.

■

Raise and lock trailer wheel stand in up position when

transporting.

■

The maximum speed for highway towing is 55 MPH

unless posted otherwise. Recommended off-road towing

is not to exceed 15 MPH or less depending on type of

terrain.

■

Place

support blocks

underneath the trailer’s bumper to

prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Towing and Transporting Safety

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 in

good operating condition and both units are mechanically

sound.

The following list of safety precautions should be followed

when towing your generator:

■

ALWAYS shutdown engine before transporting.

■

Drain fuel from generator fuel tank before towing.

■

If generator is mounted on a trailer, make sure trailer

complies with all local and state safety transportation

laws. Follow the listed

Towing & Transporting Safety

guidelines for basic towing techniques.

■

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 cold.

Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle

properly.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and

working properly.

■

DOT Requirements include the following:

Connect and test electric brake operation.

Secure portable power cables in cable tray with tie

wraps.

If your generator is trailer mounted, please

read the towing and safety requirements

listed below.

For more saftey tips, see the trailer saftey

guidelines section in this manual.

NOTE

DCA-20SPX — RULES FOR SAFE OPERATION

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 15

NOTE PAGE

PAGE 16 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

The DCA-20SPX generator is equipped with a number of safety decals (Figures 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 these decals become unreadable, replacements can be obtained from your dealer.

DCA-20SPX — GENERATOR DECALS

Figure 2. Generator Decals

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 17

DCA-20SPX — GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

PAGE 18 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Figure 4. Typical Generator Grounding Application

DCA-20SPX — INSTALLATION

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 19

Outdoor Installation

Install the generator in a area that is free of debris,

bystanders, and overhead obstructions. Make sure the

generator is on secure level ground so that it cannot slide or

shift around. Also install the generator in a manner so that

the exhaust will not be discharged in the direction of nearby

homes.

The installation site must be relatively free from moisture

and dust. All electrical equipment should be protected from

excessive moisture. Failure to do will result in deterioration

of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive

materials have a tendency to cause excessive wear to

engine and alternator parts.

Generator Grounding

To guard against electrical shock and possible damage to

the equipment, it is important to provide a good EARTH

ground.

Article 250 (Grounding) of the National Electrical Code (NEC)

provides guide lines for proper grounding and specifies that

the cable ground shall be connected to the grounding system

of the building as close to the point of cable entry as

practical.

NEC articles 250-64(b) and 250-66 set the following

grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) 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 the other

end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground

rod should be buried aminimum of 8 ft. into the ground.

When connecting the generator

to any buildings electrical

system ALWAYS consult with

a licensed electrician.

DCA-20SPX — INSTALLATION

NOTE

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.

Whenever an engine is installed indoors the exhaust fumes

must be vented to the outside. The engine should be installed

at least two feet from any outside wall. Using an exhaust

pipe which is too long or too small can cause excessive

back pressure which will cause the engine to heat excessively

and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such

as concrete) and set firmly on the foundation to isolate

vibration of the generator when it is running. The generator

must set at least 6 inches above the floor or grade level (in

accordance to NFPA 110, Chapter 5-4.1). DO NOT remove

the metal skids on the bottom of the generator. They are to

resist damage to the bottom of the generator and to maintain

alignment.

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.

CAUTION - EXHAUST HAZARD

PAGE 20 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — GENERAL INFORMATION

DCA-20SPX Whisperwatt™ Series Familiarization

Generator

The MQ Power Model DCA-20SPX is a 20 kW

generator

(Figure 5) that is designed as a high quality portable (requires

a trailer for transport) power source for telecom sites, lighting

facilities, power tools, submersible pumps and other industrial

and construction machinery.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

■

Tachometer

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Panel Light/Panel Light Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

Generator Control Panel

The “Generator Control Panel” is provided with the following:

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

3-Pole, 90 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Selector Switch

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

■■

■

Two 120/240V output receptacles (CS-6369), 50A

■■

■

Two auxilliary circuit breakers, (for CS-6369), 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Four output terminal lugs (1Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

Open Delta Excitation System

The DCA-20SPX generator is equipped with the state of the

art "

Open-Delta

" excitation system. The open delta system

consist of an electrically independent winding wound among

stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D.

During steady state loads, the power from the voltage regulator

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 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

of each phase to provide higher excitation to the exciter

section and thus better voltage response during the

application of heavy loads.

The connections of the AVR to the AC output windings are

for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation

current, offering maximum motor starting capabilities. The

excitation does not have a "

fixed ceiling

" and responds

according the demands of the required load.

Engine

The DCA-20SPX is powered by a 4 cylinder, water cooled,

direct injection,

Isuzu Model AA-4LE2 diesel engine

. This

engine is designed to meet every performance requirement

for the generator. Reference Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

Electric Governor System

The electric governor system controls the RPMs of the en-

gine. When the engine demand increases or decreases, the

governor system regulates the frequency variation to ±.25%.

Extension Cables

When electric power is to be provided to various tools or

loads at some distance from the generator, extension cords

are normally used. Cables should be sized to allow for

distance in length and amperage so that the voltage drop

between the generator and point of use (load) is held to a

minimum. Use the cable selection chart (Table 6) as a guide

for selecting proper extension cable size.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 21

DCA-20SPX — MAJOR COMPONENTS

Figure 5. Major Components

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PAGE 22 — 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 23

DCA-20SPX — GENERATOR CONTROL PANEL

The definitions below describe the controls and functions of

the DCA-20SPX

Generator Control Panel

(Figure 6).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the load

is drawing from the generator per leg selected by the

ammeter phase-selector switch.

3. AC Voltmeter – Indicates the output voltage present at

the

U,O, and V Output Terminal Lugs

4. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

5. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the

load connected to any phase of the output terminals, or

to be switched off. This switch does not effect the

generator output in any fashion, it is for current reading

only.

6. Main Circuit Breaker – This three-pole, 90A main

breaker is provided to protect the the

U,O, and V Output

Terminal Lugs

from overload.

Located behind the generator control panel is the

Generator

Control Box

. This box contains some of the necessary

electronic components required to make the generator

function.

The Control Box is equipped with the following major

components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Switch

■■

■

Single Phase Circuit Breaker

Figure 6. Generator Control Panel

Remember the

overcurrent

relay

monitors the current

flowing from the

U,O and V

Output Terminal Lugs

to the

load.

In the event of a short circuit or over current condition, it will

automatically trip the 90 amp main breaker.

To restore power to the

Output Terminal Panel

, press the

reset

button on the overcurrent relay and place the

main

circuit breaker in the

closed

position (ON).

NOTE

OFF

DECREASE

INCREASE

PAGE 24 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Figure 7. Engine Operating Panel

DCA-20SPX — ENGINE OPERATING PANEL

AUTO MANUAL

OFF/RESET

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

OVERCRANK

OVERSPEED

ENGINE RUNNING

MOOOOO-20001Q

RPM

03000

20001000

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 25

DCA-20SPX — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of

the DCA-20SPX

Engine Operating Panel

(Figure 7).

1. Panel Light – Normally used in dark areas or at night

time. When activated, panel lights will illuminate. When

the generator is not in use be sure to turn the panel

light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control

panel light.

3. Oil Pressure Gauge – During normal operation this

gauge be should read between 35 to 65 psi. (241~448

kPa). When starting the generator the oil pressure may

read a little higher, but after the engine warms up the oil

pressure should return to the correct pressure range.

4. Water Temperature Gauge – During normal operation

this gauge should read between 180° and 221°F (82°

~105°C)

5. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides

current for generator’s control circuits and battery

charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s

when the rated load is applied. In addition a built in hour

meter will record the number of operational hours that

the generator has been in use.

8. Fuel Filter Water Level Alarm Lamp– This lamp will

illuminate when an excessive amount of water has

accumulated in fuel filter. Drain water in the strainer

immediately if this lamp is on.

A. MPEC Control Switch – This switch controls the

running of the unit. If this switch is set to the

OFF/RESET position, the unit will not run. When this

switch is set to the MANUAL position, the generator

will start immediately.

If the generator is to be connected to a building’s AC

power source via an automatic transfer switch

(isolation), place the switch in the AUTO position. In

this position, should an outage occur, the 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 further instructions for

the correct installation of the auto-start contacts of the

generator to the ATS.

B. Low Oil Pressure – Indicates the engine pressure has

fallen below 14 psi (97 kPa). The oil pressure is detected

using variable resistive values from the oil pressure

sending unit. This is considered a

major

fault.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 221

F. (105°C). The engine

temperature is detected using variable resistive values

from the temperature sending unit. This is considered

major

fault.

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times,

and has failed to start. The number of cycles and

duration are programmable. It is pre-set at 3 cycles

with a 10 second duration. This is considered a

major

fault.

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

major

fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

If the engine does not engage (start) by the third attempt,

the engine will be shutdown by the engine controller’s

Over

Crank Protection

mode. If the engine engages at a speed

(RPM's) that is not safe, the controller will shutdown the

engine by initializing the

Over Speed Protection

mode.

Also the engine controller will shut down the engine in the

event of low oil pressure, high coolant temperature, low

coolant level, and loss of magnetic pickup. These conditions

can be observed by monitoring the LED status indicators on

the front of the controller module.

9. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical row of status LED's (inset),

that when lit, indicate that an engine malfunction (fault)

has been detected. When a fault

has been detected the engine

controller will evaluate the fault

and all major faults will shutdown

the generator. During

cranking

cycle

, The MPEC will attempt to

crank the engine for 10 seconds

before disengaging.

PAGE 26 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Output Terminal Familiarization

The “

Output Terminal Panel

” (Figure 8) is provided with the

following:

■■

■

Two 120/240V output receptacles (CS-6369), 50A

■■

■

Two auxilliary circuit breakers, (for CS-6369), 50A

■■

■

Two 120V GFCI receptacles @ 20 amp

■■

■

Two GFCI circuit breakers @ 20 amps

■■

■

Four Output Terminal Lugs ( U, O, V and Ground)

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located

on the right-hand side (left from control panel) of the generator.

Lift up on the cover to gain access to receptacles and terminal

lugs.

Figure 8. Output Terminal Panel

DCA-20SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 27

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)

recepacles provided on the output terminal panel. These

receptacles can be accessed in any

voltage selector switch

position. Each receptacle is protected by a 20 amp circuit

breaker. These breakers are located directly above the GFCI

receptacles. Remember the load output (current) of both

GFCI receptacles is dependent on the load requirements of

the U, O, and V output terminal lugs.

Pressing the

reset

button resets the GFCI receptacle after

being tripped. Pressing the

Test Button

(See Figure 9) in

the center of the receptacle will check the GFCI function.

Both receptacles should be tested at least once a month.

Figure 9. G.F.C.I. Receptacle

Each auxilliary 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 requirements of the

Output Terminal Lugs

Turn the

voltage regulator control knob

(Figure 11) on the

control panel to obtain the desired voltage. Turning the knob

clockwise will

increase

the voltage, turning the knob counter-

clockwise will

decrease

the voltage.

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-20SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock

(CS-6369) recepacles (Figure 10) provided on the output

terminal panel.These receptacles can

only

be accessed

when the voltage selector switch is placed in the

single-

phase 240/120 position.

Figure 11. Voltage Regulator Control Knob

Figure 12. Plastic Face Plate (Output Terminal Lugs)

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The

Output Terminal Lugs

are protected by a plastic face

plate cover (Figure 12). Un-screw the securing bolts and lift

the plastic terminal cover to gain access to the terminal

enclosure.

After the load wires have been securely attached to the

terminal lugs, reinstall the plastic face plate.

PAGE 28 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Figure 13. Connecting Loads

Connecting Loads

Loads can be connected to the generator by the

Ouput

Terminal Lugs

or the convenience receptacles (Figure 13).

Make sure to read the operation manual before attempting

to connect a load to the generator.

To protect the output terminals from overload, a

3-pole, 90A

main

circuit breaker is provided. Make sure to

switch ALL circuit breakers to the OFF position prior to

starting the engine.

DCA-20SPX — OUTPUT TERMINAL PANEL FAMILIARIZATION

Over Current Relay

over current relay

(Figure 14) 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 cur-

rent relay must be pressed. The over current relay is lo-

cated in the control box.

Figure 14. Over Current Relay

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 29

DCA-20SPX — LOAD APPLICATION/MAXIMUM AMPERAGE

Single Phase Load

Always be sure to check the nameplate on the generator

and equipment to insure the wattage, amperage,

frequency

and voltage requirements are satisfactorily supplied by the

generator for operating the equipment.

Generally, the wattage listed on the nameplate of the

equipment is its rated output. Equipment may require 130—

150% more wattage than the rating on the nameplate, as

the wattage is influenced by the efficiency, power factor and

starting system of the equipment.

Motors and motor-driven

equipment draw much greater

current for starting than during

operation.

When connecting ordinary power tools, a capacity of up to

the generating set’s rated output (kW) multiplied by 0.8 can

be used.

If wattage is not given on the

equipment's name plate,

approximate wattage may be

determined by multiplying

nameplate voltage by the

nameplate amperage.

The power factor of this generator is 0.8. See Table 5 below

when connecting loads.

■■

■

When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up to

the generating set’s rated output (kW) can be used.

■■

■

When connecting a fluorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW)

multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

pay close attention to the required starting current

capacity.

WATTS = VOLTAGE x AMPERAGE

NOTE

An inadequate size connecting cable which cannot carry the

required 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

electrician

must install an

isolation

(transfer)

switch

. Serious damage to the building’s

electrical system may occur without this transfer switch.

DANGER - ELECTRICAL SYSTEM HAZARDS

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Table 7 describes the generator’s current output capability.

PAGE 30 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

UOV Terminal Output Voltages

240/120V output voltages can be obtained using the

Output

Terminal Lugs

The voltage regulator (VR) allows the user to increase or

decrease the selected voltage.

1Ø 240 Output Terminal Lug Voltages

1. Connect the load wires to the

Output Terminal Lugs

shown in (Figure 17)

Figure 17. Output Terminal Lugs

240 Single Phase Connections

2. Turn the voltage regulator knob (Figure 18) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

Figure 18. Voltage Regulator Knob (139V/240V)

2. Turn the voltage regulator knob (Figure 18) clockwise to

increase voltage output, turn counterclockwise to

decrease voltage output.

How to Read the Output Terminal 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)

Figure 15. AC Ammeter

Change-Over Switch

Reading Amperage

To determine the amperage at a terminal lug, set the

AC Ammeter Change-Over

Switch

to the appropriate

setting (Figure 15) to activate the

AC Ammeter Gauge

(Figure 16) and read the available amperage at the terminal

lug.

For example, to measure the amperage at the U

terminal lug, set the

AC Ammeter Change-Over Switch

U and read the AC Ammeter Gauge.

The

ammeter

gauge will only

show a reading when the

Output

Terminal Lugs

are connected

to a load and in use.

NOTE

DCA-20SPX — GAUGE READING/ TERMINAL PANEL CONNECTIONS

1Ø 120 Output Terminal Lug Voltages

1. Connect the load wires to the

Output Terminal Lugs

shown in (Figure 19)

Figure 19. Output Terminal Lugs

120 Single Phase Connections

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 31

DCA-20SPX — SETUP

Figure 20. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is

clean. If the oil is not clean, drain the oil 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.

Other types of motor oils may be substituted if they meet

the following requirements:

■■

■

API Service Classification CC/SC

■■

■

API Service Classification CC/SD

■■

■

API Service Classification CC/SE

■■

■

API Service Classification CC/SF

Circuit Breakers

To protect the generator from an overload, a 3-pole, 90 amp,

main

circuit breaker is provided to protect the

U,O, and V

Output Terminals

from overload. In addition two single-pole,

20 amp

GFCI

circuit breakers are provided to protect the

GFCI receptacles from overload. Two 50 amp

load

circuit

breakers have also been provided to protect the auxiliary

receptacles from overload. Make sure to switch ALL circuit

breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through 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 of engine oil.

Figure 21. Internal Fuel Tank System

Refilling the Fuel System

Fuel Check

This generator has an internal fuel tank located inside the

trailer frame and may also be equipped with an optional

environmental fuel tank (Figure 21).

ALWAYS

fill the fuel

tanks with clean fresh

#2 diesel fuel.

DO NOT fill the fuel

tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing

fuel.The fuel tank cap must be closed tightly after filling.

Handle fuel in a safety container. If the container does not

have a spout, use a funnel. Wipe up any spilled fuel

immediately.

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

CAUTION - REFUELING THE GENERATOR

Fuel spillage on a

hot

engine can cause a

fire

explosion

If fuel spillage occurs, wipe up the spilled fuel completely

to prevent fire hazards. NEVER smoke around or near the

generator.

DANGER - EXPLOSION/FIRE HAZARDS

-40

-30

-10

-20

-22

-40

-4

-14

032

104

122

10W40

ARCTIC OIL

5W30

10W/40

15W30

10W30

10W

20W40

OIL: SAE

Table 8. Recommended Motor Oil

PAGE 32 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — SETUP

Refueling Procedure:

1. Level Tanks – Make sure fuel cells are level with the

ground. Failure to do so will cause fuel to spill from the

tank before reaching full capacity (Figure 22).

Figure 22. Only Fill on Level Ground

ONLY! use

#2 diesel fuel

when

refueling.

NOTE

3. 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 24).

Figure 24. Full Fuel Tank

Figure 25. Fuel Expansion

2. Remove 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 into the tank.

CAUTION - REFUELING THE GENERATOR

Diesel fuel and its vapors are dangerous

to your health and the surrounding

environment. Avoid skin contact and/or

inhaling fumes.

WARNING - RESPIRATORY HAZARDS

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 25).

CAUTION - REFUELING THE GENERATOR

Figure 23. Fueling the Generator

If generator is equipped with an

environmental fuel tank, reference

Figures 24 and 25.

NOTE

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 33

Coolant (Antifreeze/Summer Coolant/Water)

ISUZU recommends antifreeze/summer coolant for use in

their engines, which can be purchased in concentrate (and

mixed with 50% demineralized water) or pre-diluted. See

the ISUZU Engine Owner's Manual for further details.

Day-to-day addition of coolant is done from the recovery

tank. When adding coolant to the radiator, DO NOT remove

the radiator cap until the unit has completely cooled. See

Table 9 for engine, radiator, and recovery tank coolant

capacities. Make sure the coolant level in the recovery tank

is always between the "H" and the "L" markings.

Operation Freezing Weather

When operating in freezing weather, be certain the proper

amount of antifreeze (Table 10) has been added.

Cleaning the Radiator

The engine may overheat if the radiator fins become

overloaded with dust or debris. Periodically clean the radiator

fins with compressed air. Cleaning inside the machine is

dangerous, so clean only with the engine turned off and the

negative

battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

accordance with the ISUZU Engine Owner's Manual.

Fan Belt Tension

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 26) when depressed with the thumb as shown

below.

Figure 26. Fan Belt Tension

DCA-20SPX — SETUP

When the antifreeze is mixed with

water, the antifreeze mixing ratio

must be

less than 50%.

NOTE

If adding coolant/antifreeze mix to the

radiator, DO NOT remove the radiator cap

until the unit has completely cooled. The

possibility of

hot!

coolant exists which

can cause severe burns.

WARNING - BURN HAZARDS

NEVER place hands near

the belts or fan while the

generator set is running.

CAUTION - ROTATING PARTS

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PAGE 34 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — SETUP

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the

MPEC Control Switch

is in either

the MANUAL position. ALWAYS make sure that the

MPEC

Control Switch

is in the OFF/RESET position when

connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will ensure

a good connection and will help prevent corrosion around

the battery terminals.

Figure 27. Battery Connections

ALWAYS

disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

Inadequate battery connections may cause poor starting

of the generator, and create other malfunctions.

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 corrision and damage the

alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring

or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for

wear and tightness. Tighten all hose clamps and check hoses

for leaks.

If any hose (

fuel

oil

) lines are defective replace them

immediately.

If the battery cable is connected

incorrectly, electrical damage to the

generator will occur. Pay close

attention to the polarity of the

battery when connecting the

battery.

NOTE

Battery

This unit is of negative ground DO NOT connect in reverse.

Always maintain battery fluid level between the specified

marks. Battery life will be shortened, if the fluid level are not

properly maintained. Add only distilled water when

replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables

are loose. Poor contact may result in poor starting or

malfunctions.

Always

keep the terminals firmly tightened.

Coating the terminals with an approved battery terminal

treatment compound. Replace battery with only

recommended type battery.

The battery is sufficiently charged if the specific gravity of

the battery fluid is 1.28 (at 68° F). If the specific gravity

should fall to 1.245 or lower, it indicates that the battery is

dead and needs to be recharged or replaced.

Before charging the battery with an external electric source,

be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 27) are properly

connected to the battery terminals as shown below. The Red

Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal

of the battery.

CAUTION - BATTERY SERVICING SAFETY

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 35

Figure 32. Frequency Meter (Hz)

4. The generator's frequency meter (Figure 32) should be

displaying the 60 cycle output frequency in HERTZ.

3. Verify that the Engine Running

status LED on the MPEC unit

(Figure 31) is ON (lit) after the

engine has been started.

Figure 31. Engine Running LED (ON)

Manual Start-up

Procedure

Figure 30. MPEC Control Switch

(Manual Position)

DCA-20SPX — GENERATOR START-UP PROCEDURE (MANUAL)

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

Before Starting

Figure 29. Engine Enclosure Doors

1. Place the

main, G.F.C.I.,

and

aux.

circuit breakers

(Figure 28) in the OFF position prior to starting the engine.

Figure 28. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Connect the load to the

receptacles

the

output

terminal lugs

as shown in Figure 13. These load

connection points can be found on the output terminal

panel and the output terminal panel’s hard wire hookup

panel.

3. The output terminal lugs are protected by a plastic cover.

Remove this cover to gain access to the terminals.

Tighten terminal nuts securely to prevent load wires from

slipping out.

4. Close all engine enclosure doors (Figure 29).

CAUTION - LETHAL EXHAUST HAZARD

2. Once the engine starts, let it engine run for 1-2 minutes.

Listen for any abnormal noises. If any abnormalities

exists shutdown the engine and correct the problem.

1. Place the

MPEC Control Switch

in the MANUAL

position to start the engine (Figure 30).

NEVER!

manually start the engine with the

main

GFCI

auxiliary

circuit breakers in the ON (closed) position.

WARNING - STARTING THE GENERATOR

PAGE 36 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — GENERATOR START-UP PROCEDURE (MANUAL)

Figure 34. Voltage Adjust Control Knob

Figure 35. Ammeter

(No Load)

6. The ammeter (Figure 35) 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.

5. The generator's AC-voltmeter (Figure 33) will display the

generator’s output in VOLTS. If the voltage is not within

the specified tolerance, use the voltage adjustment

control knob (Figure 34) to increase or decrease the

desired voltage.

Figure 33. Voltmeter

Figure 38. Engine

Tachometer Gauge

9. The

tachometer gauge

(Figure 38)

will indicate the speed of the engine

when the generator is operating.

Under normal operating conditions

this speed is approximately 1800

RPM’s.

8. The

coolant temperature gauge

(Figure 37) will indicate the

coolant temperature. Under

normal operating conditions the

coolant temperature should be

between 180~221 °F (82~105 °C),

Green Zone

Figure 37. Coolant

Temperature Gauge

7. The engine oil pressure gauge

(Figure 36) will indicate the oil

pressure of the engine. Under

normal operating conditions the

oil pressure is approximately 35

to 65 psi. (241~448 kPa). When

starting the generator. Figure 36. Oil

Pressure Gauge

Figure 39. Main, Aux. and GFCI

Circuit Breakers (ON)

10. Place the

main

GFCI

, and

aux

. circuit breakers in the

ON position (Figure 39).

11. Observe the generator's ammeter

(Figure 40) 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 40. Ammeter

(Load)

12. The generator will run until manually stopped or an

abnormal condition occurs.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 37

1. Perform steps 1 through 5 in the

Before Starting

section.

2. Place the

MPEC Control Switch

(Figure 41) in the AUTO

position

3. Continue operating the generator as outlined in the

Manual Start-up

Procedure

(start at step 3).

Figure 41. MPEC Control Switch (AUTO)

When the generator is set in the

AUTO mode, the generator will

automically start

in the event of

comercial power falling below a

prescribed level by means of a

contact closure that is generated

automatically by a transfer switch.

NOTE

Starting (Auto Mode)

Before connecting this generator to any

building’s 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 HAZARDS

When connecting the generator to a isolation (transfer)

switch, ALWAYS have power applied to the generator's

internal battery charger. This will ensure that the engine

will not fail due to a dead battery.

CAUTION - BACKUP GENERATOR USE

When running the generator in the AUTO mode, remember

the generator can start up at any time without warning.

NEVER attempt to perform any maintenance when the

generator is in the auto mode.

WARNING - AUTO MODE MAINTENANCE

DCA-20SPX — GENERATOR START-UP PROCEDURE (AUTO MODE)

When starting generator in AUTO mode use the "

Manual

Start-up" procedure except where noted (see below).

PAGE 38 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers

as shown in Figure 39 to the OFF position.

2. Let the engine cool by running it at low speed for 3-5

minutes with no load applied.

3. Place the

MPEC Control Switch

(Figure 42) to the

OFF/RESET position.

Figure 42. MPEC 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

components that may have occured during operation.

Emergency Shutdown Procedure

1. Place the

MPEC Control Switch

switch (Figure 42) to

the OFF/RESET position.

2. To shut-down the engine in the event of an emergency,

switch the

MAIN

GFCI

and

LOAD

(Figure 39) circuit

breakers to OFF position.

DCA-20SPX — GENERATOR SHUT-DOWN PROCEDURES

NEVER stop the engine suddenly except in an emergency.

WARNING -

SHUTTING DOWN THE GENERATOR

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 39

DCA-20SPX — MAINTENANCE

Service Daily

If the engine is operating in very

dusty

dry grass

conditions, a clogged air cleaner will result. This can lead to

a loss of power, excessive carbon buildup in the combustion

chamber and high fuel consumption. Change air cleaner

frequently

if these conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season

and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate

in the bottom of the tank. Occasionally inspect the fuel

tank for water contamination and drain the contents if

required.

During cold weather, the more empty volume inside the

tank, the easier it is for water to condense. This can be

reduced by keeping the tank full with diesel fuel.

General Inspection

Prior to each use, the generator should be cleaned and

inspected for deficiencies. Check for loose, missing or

damaged nuts, bolts or other fasteners. Also check for fuel,

oil, and coolant leaks. Use Table 11 as a general maintenance

guideline Engine Side (Refer to the Engine Instruction

Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the

heavy duty paper element with light spray of compressed

air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air

cleaner element is clogged, air intake restriction becomes

greater and the dust indicator signal shows RED meaning

the element needs changing or service. After changing the

air element, press the dust indicator button to reset the

indicator.

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PAGE 40 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — MAINTENANCE

Generator Storage

For longe term storage of the generator the following is

recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer

if necessary.



Completely drain the oil from the crankcase and refill if

necessary with fresh oil.



Clean the entire generator, internal and external.



Cover the generating set and store in a clean, dry place.



Disconnect the battery.



Make sure engine coolant is at proper level.



If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block

and completely remove the tires.

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at

the lower part of the radiator and drain coolant. Open the

radiator cap while draining. Remove the overflow tank

and drain.



Check hoses for softening and kinks. Check clamps for

signs of leakage.



Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT

clean radiator core with any objects, such as a

screwdriver.



Tighten both cocks and replace the overflow tank.



Replace with coolant as recommended by the engine

manufaturer.



Close radiator cap tightly.

Air Removal

If air enters the fuel injection system of a diesel engine,

starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system

according to the following procedure. See the

VOLVO Engine

Manual

for details.

To restart after running out of fuel, turn the switch to the

“ON” position for 15-30 seconds. Try again, if needed. This

unit is equipped with an automatic air bleeding system.

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 the generator is level. The oil level

must be between the two notches on the dipstick as shown

in Figure 31.

Replacing Oil Filter



Remove the old oil filter.



Apply a film of oil to the gasket on the new oil filter.



Install the new oil filter.



After the oil cartridge has been replaced, the engine oil

will drop slightly. Run the engine for a while and check

for leaks before adding more oil if needed. Clean

excessive oil from engine.

Allow engine to

cool

when flushing out

radiator. Flushing the radiator while hot

could cause serious burns from water or

steam.

WARNING - BURN HAZARDS

Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 500

hours or so.



Loosen the drain plug at the lower top of the fuel filter.

Drain the fuel in the fuel body together with the mixed

water. DO NOT spill the fuel during disassembly.



Vent any air.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove

dust or water in the strainer cap and wash it in gasoline.

Securely fasten the fuel strainer cap so that fuel will not

leak. Check the fuel strainer every 200 hours of operation or

once a month.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 41

DCA-20SPX — MAINTENANCE

To ensure adequate starting

capability, always have power

applied to the generator's

internal battery charger

NOTE

Figure 43. Battery Charger &

Jacket Water Heater Power Connections

Jacket Water Heater and Internal Battery Charger

120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC,

20 amp input receptacles located on the output terminal

panel.

The purpose of these receptacles is to provide power via

commercial power to the

jacket water heater

and

internal

battery charger

These receptacles will ONLY 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 (See Table 6).

When using the generator in

hot

climates there is no reason

to apply power to jacket water heater. However, if the

generator will be used in

cold

climates it is always a good

idea to apply power to the jacket water heater at all times. To

apply power to the jacket water heater simply apply power to

the jacket water heater receptacle via commercial power

using an power cord of adequate size.

If the generator will be used daily, the battery should normally

not require charging. If the generator will be idle (not used)

for long periods of time, apply power to the battery charger

receptacle via commercial power using an power cord of

adequate size.

PAGE 42 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — TRAILER MAINTENANCE

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the

diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug

nuts. See Table 16 and Figure 59 for lug nut tightening

and sequence.

13. Axle - Indicates the maximum weight the axle can sup-

port in pounds, and the diameter of the axle expressed

in inches. Please note that some trailers have a double

axle. This will be shown as 2-6000 lbs., meaning two

axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension

used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided

with the 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 intended to provide the user with generic

trailer service and maintenance information. The service and

maintenance guidelines referenced in this section refer to a

wide range of trailers.

Remember periodic inspection of the trailer will ensure safe

towing of the generator and will prevent personal injury and

damage to the equipment.

The definitions below describe some of the major components

of a typical trailer that would be used with the DCA-20SPX

Whisperwatt

™

Generator.

1. Fuel Cell - Provides an adequate amount of fuel for the

equipment in use. Fuel cells must be empty when trans-

porting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to

the rear bumper (reflector).

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound

requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 43

DCA-20SPX — TRAILER MAINTENANCE

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 44) should not require any

special attention with the exception of routine maintenance

such as shoe and lining replacement. Brake lines should be

periodically checked for cracks, kinks, or blockage.

Figure 44. Hydraulic Brake Components

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat

properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

brakes more frequently.

Figure 44 displays the major hydraulic surge brake

components that will require inspection and maintenance.

Please inspect these components as required using steps 1

through 8 and Table 15 as listed below:

Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack

stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot

at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

star wheel of the adjuster assembly to expand the brake

shoes.

5. Adjust the brake shoes outward until the pressure of the

lining against the wheel drum makes the wheel difficult

to turn.

6. Adjust, rotate the star wheel in the opposite direction

until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to

the ground.

8. Repeat steps 1 through 7 on the remaining brakes.

Actuator

Hydraulic surge braking requires the installation of an actuator

at the tongue of the trailer. Remember the

surge

push

the trailer toward the tow vehicle automatically synchronizes

the trailer brakes with the tow vehicle brakes. As the trailer

pushes against the tow vehicle the actuator telescopes

together and applies force to the master cylinder, supplying

hydraulic pressure to the trailer brakes.

Periodically check and test the surge “

actuator

” to make

sure that it is functioning correctly. Never use an undersize

actuator.

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PAGE 44 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing the

trailer wheels it is important the wheels, tires, and axle are

properly matched.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation DO NOT

bleed air from tires when they are

hot!

. Check inflation

pressure weekly during use to insure the maximum tire life

and tread wear.

Table 13 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

Suspension

The

leaf suspension

springs and associated components

(Figure 45) should be visually inspected every 6,000 miles

for signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 14.

Figure 45. Major Suspension Components

DCA-20SPX — TRAILER MAINTENANCE

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the

rim is cracked, the air pressure in the inner

tube may cause pieces of the rim to

explode (break off) with great force and

cause serious eye or bodily injury.

CAUTION - REPAIRING TRAILER WHEELS

ALWAYS

wear safety glasses when

removing or installing force fitted parts.

Failure to comply may result in serious

injury.

CAUTION - EYESIGHT HAZARD

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DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 45

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Figure 46. Wheel Lug Nuts

Tightening Sequence

DCA-20SPX — TRAILER MAINTENANCE

NOTE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel

mounting torque on the trailer. Be sure to use only the

fasteners matched to the cone angle of the wheel. Proper

procedure for attachment of 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 as defined by Table 15.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

stnemeriuqeReuqroTeriT.51elbaT

eziSleehWssaPtsriF

SBL-TF

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

PAGE 46 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — TRAILER WIRING DIAGRAM

Figure 47. Trailer/Towing Vehicle Wiring Diagram

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 47

DCA-20SPX — GENERATOR WIRING DIAGRAM

Figure 48. Generator Wiring Diagram

PAGE 48 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — ENGINE WIRING DIAGRAM

Figure 49. Engine Wiring Diagram

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 49

GNITOOHSELBUORTENIGNE.61ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.tratstonseodenignE

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

foytisocsivhgihylevissecxE

woltalioenigneroleuf

?erutarepmet

.lioenigneroleufdeificepsehtesU

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip .ecalperroriapeR

morfkaelnoisserpmoC

?rednilyc

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

.nurtonseodretratS

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

DCA-20SPX — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use Table 16 shown below for diagnosis of the engine. If the problem cannot be remedied, consult our company's

business office or service plant.

PAGE 50 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

.htoomstonsinoituloverenignE

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?tungniniaterepip .tunnethgiT

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

?erusserp .tsujdA

rokcutselzzonnoitcejnI

?deggolc .ecalperroriapeR

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

sagtsuahxeeulbroetihwrehtiE

.devresbosi

?lioenigneevissecxE .leveldeificepsehtotecudeR

ronrowrenildnagnirnotsiP

?kcuts .ecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.tuptuotneicifeD

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?gnizieseb .ecalperroriapeR

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

DCA-20SPX — TROUBLESHOOTING (ENGINE)

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 51

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use Table 17 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our

company's business office or service plant.

DCA-20SPX — TROUBLESHOOTING (GENERATOR)

GNITOOHSELBUORTROTARENEG.71ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 52 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a

breakdown, use Table 18 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor

Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.81ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

sithgilerusserpliowoL

.no

?levelliowoL.levelliolliF

?eruliaftinugnidneserusserpliO .tinugnidneseru

sserplioecalpeR

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?detrohseriW.eriwriaper/tcepsnI

sithgilleve

ltnaloocwoL

)dellatsnIyllanoitpO(.no

?leveltnaloocwoL.leveltnalooclliF

?eruliaftinugnidneS .tinugnidneseca

lpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

erutrepmettnaloochgiH

.nosithgil

?tcerrocninoisnettlebnaF .t

lebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?neposrooD.srood

esolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliafhctiwserutarepmeT .hctiwseruta

repmetecalpeR

.nosithgilknarcrevO

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenrellortnoC.relaedotrefeR

nosithgildeepsrevO

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

sujdA

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenign

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipci

tengaM .pukcipcitengamnaelC

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 53

NOTE PAGE

PAGE 54 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

remarks used in the Parts section of this manual. Use the

help numbers found on the back page of the manual if there

are any questions.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the

same assembly or kit, which is indicated by a note in the

“Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate

multiple part numbers, which are in effect for the same

general item, such as different size saw blade guards in

use or a part that has been updated on newer versions

of the same machine.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a

part that has not been assigned a formal part number

at the time of publication.

A blank entry generally indicates that the item is not sold

separately or is not sold by Multiquip. Other entries will

be clariﬁed in the “Remarks” Column.

NOTICE

The contents and part numbers listed in the parts

section are subject to change without notice. Multiquip

does not 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. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other

parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold

separately. Other entries will be clariﬁed in the “Remarks”

Column.

REMARKS Column

Some of the most common notes found in the “Remarks

”

Column are listed below. Other additional notes needed

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

same unique symbol will be included when this item is

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break — Used to list an effective serial

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW”

“S/N XXXX AND ABOVE”

“S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use — Indicates that the part

is used only with the speciﬁc model number or model

number variant listed. It can also be used to show a

part is NOT used on a speciﬁc model or model number

variant.

Indicated by:

“XXXXX ONLY”

“NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can

be purchased at any hardware shop or made out of

available items. Examples include battery cables, shims,

and certain washers and nuts.

“Not Sold Separately” — Indicates that an item cannot

be purchased as a separate item and is either part of an

assembly/kit that can be purchased, or is not available

for sale through Multiquip.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 55

DCA-20SPX — SUGGESTED SPARE PARTS

Part number on this Suggested Spare Parts list

may supercede/replace the P/N shown in the text

pages of this book.

NOTE

DCA-20SPX WHISPER WATTGENRATOR

W/ISUZU AA-4LE2 DIESEL ENGINE

1 TO 3 UNITS

Qty.P/N Description

1 ......... B1312500403 ..... HOSE, RADIATOR UPPER

1 ......... B1312500503 ..... HOSE, RADIATOR LOWER

1 ......... 0602011079 ....... RADIATOR CAP

1 ......... 0605505070 ....... FUEL CAP

1 ......... 0602122272 ....... UNIT, OIL PRESSURE

1 ......... 0602123275 ....... UNIT, WATER TEMPERATURE

6 ......... 8943692993 ....... FILTER, FUEL CARTRIDGE

6 ......... 8944370220 ....... FILTER, FUEL (FUEL PUMP))

6 ......... 8944567411 ....... FILTER, OIL CARTRIDGE

3 ......... 0602046611 ....... FILTER, AIR (ELEMENT)

1 ......... 0601870440 ....... CIRCUIT BREAKER, 1P, 120V @ 20A

1 ......... 0601870441 ....... CIRCUIT BREAKER, 2P, 250V @ 50A

1 ......... LY2DUS12VDC .. RELAY

1 ......... 8972249990 ....... FAN BELT

1 ......... 0601820626 ....... AUTOMATIC VOLTAGE REGULATOR

1 ......... 1601840073 ....... RHEOSTAT

1 ......... 0601840121 ....... KNOB, RHEOSTAT

PAGE 56 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX — GENERATOR ASSY.

GENERATOR ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 57

DCA-20SPX — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 B0110100102 ROTOR ASSY. ..................................... 1 ............. INCLUDES ITEMS W/ #

1-1#FIELD ASSY. ....................................... 1 ............. NOT SOLD SEPARATELY

1-2#7961025004 RECTIFIER 1

1-3#0601822630 SURGE ABSORBER 1

1-4#8001070003 FAN 1

1-5#8351611004 COUPLING DISC 2

1-6#8351612004 COUPLING HUB WASHER 1

1-7#B1112300003 BALANCING PLATE ............................ 1 ............. PURCHASE ITEM 1-10 AS A SET

1-8#0010310025 HEX HEAD BOLT 4

1-9#0042510000 SPRING WASHER 4

1-10#0601000209 BALANCING WEIGHT KIT 1

1-11#0071906308 BEARING 1

2 0012308035 HEX HEAD BOLT 6

3 0070506803 BEARING 1

4 B0130100803 STATOR ASSY. 1

4-1 0845041904 GROMMET 1

5 8431350003 FIELD ASSY. EXCITER 1

6 0016008045 HEX SOCKET HEAD CAP SCREW 3

7 0042508000 SPRING WASHER 3

8 8351315003 END BRACKET 1

9 0017108035 HEX HEAD BOLT 6

10 8351312004 PACKING 1

11 8351331004 SUCTION COVER 1

12 0017106016 HEX HEAD BOLT 3

13 0012310030 HEX HEAD BOLT 6

14 B0155400204 FAN COVER 1

15 0340406040 HEX HEAD BOLT 1

16 0041206000 PLAIN WASHER 1

17 0600815000 NUT 1

18 0805083204 RUBBER SUSPENSION 2

19 0207010000 HEX NUT 2

PAGE 58 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 59

DCA-20SPX— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 0602120095 TACHOMETER 1

2 0602122093 OIL PRESSURE GAUGE 1

3 0602123090 WATER TEMPERATURE GAUGE 1

4 0602121080 CHARGING AMMETER 1

5 0602125090 FUEL GAUGE 1

6 0602103092 ALARM LAMP 1

6A 0601810245 BULB, DC18V 1

7 9826800370 PANEL LIGHT ................................................ 1 ......... REPLACES P/N 0601810141

8 0601831330 PANEL LIGHT SWITCH 1

9 0601831340 SWITCH 1

10 ECU9988N220V CONTROLLER ............................................... 1 .......... REPLACES P/N 0602202545

11 0207004000 HEX NUT 2

11A 0027104040 MACHINE SCREW 2

PAGE 60 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— CONTROL BOX ASSY.

CONTROL BOX ASSY. (S/N 7800001~7800129)

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 61

DCA-20SPX— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 B1214003102 CONTROL BOX 1

2 0601870433 CIRCUIT BREAKER 3P, 90 AMPS 1

3 0021004075 MACHINE SCREW 4

4 0601842384 RESISTOR, 20W 50 OHM 1

5 0027104010 MACHINE SCREW 2

6 0601823240 RECTIFIER, DE45 3

7 0027104040 MACHINE SCREW 1

8 0601815759 TERMINAL BOARD 1

9 0027104020 MACHINE SCREW 2

10 0601820626 AUTOMATIC VOLTAGE REGULATOR 1

11 0027105016 MACHINE SCREW 4

12 0601801123 CURRENT TRANSFORMER, 150/5A 2

13 0027106020 MACHINE SCREW 4

14 M1213500203 CONTROL BOX COVER 1

15 0016906015 HEX HEAD BOLT 4

16 0226900450 EDGING 1

17 0016906015 HEX HEAD BOLT 8

17A 0040506000 TOOTHED WASHER 1

18 M1223000403 CONTROL PANEL 1

19 0601807641 FRENQUENCY METER, 45~65Hz 240V 1

20 0601806844 AC AMMETER, 0-150A 1

21 0601801040 AMMETER CHANGE-OVER SWITCH 1

22 0601800271 AC VOLTMETER, 0~300V 1

23 0601840073 RHEOSTAT (VR), 2W 1K OHM 1

24 0601840121 KNOB 1

25 M1223100004 STOPPER 1

26 0027105010 MACHINE SCREW 2

27 0027105010 MACHINE SCREW 4

28 0845056404 SET SCREW 1

29 0080200007 SNAP RING 1

30 8973259120 ENGINE CONTROLLER ................................. 1 ......... REPLACES P/N 0602202523

31 0016906015 HEX HEAD BOLT 2

31A 0207006000 HEX NUT 2

32 5825500290 RELAY ............................................................ 2 ......... REPLACES P/N 0602201400

33 8942481610 GLOW RELAY ................................................ 1 ......... REPLACES P/N 0602202502

34 0027105016 MACHINE SCREW 4

35 0601826031 RELAY 1

36 0027104010 MACHINE SCREW 2

37 PTF08A BASE ............................................................. 1 ......... REPLACES P/N 0601823109

37A LY2DUS12VDC RELAY ............................................................ 1 ......... REPLACES P/N 0601827656

37B PYCA1 CLIP ............................................................... 1 ......... REPLACES P/N 0601824400

38 0601823143 BASE, PYF-08A 2

38A 0601824518 RELAY 2

38B PYCA1 CLIP ............................................................... 2 ......... REPLACES P/N 0601824400

39 0027104020 MACHINE SCREW 8

PAGE 62 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 63

DCA-20SPX— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 M1923200044 ENGINE, ISUZU AA-4LE2 DA-05 1

1A 8972249990 FAN BELT ...................................................... 1 ......... REPLACES P/N 0602011430

1-1 8944567411 OIL FILTER CARTRIDGE .............................. 1 ......... REPLACES P/N 0602041210

2 M1303200304 ENGINE FOOT 1

3 M1305200204 ENGINE FOOT 1

4 0010310025 HEX HEAD BOLT 8

5 0040010000 WASHER, LOCK 8

6 0041210000 WASHER, FLAT 8

7 0605000066 RUBBER SUSPENSION 2

8 0207010000 HEX NUT 2

9 M1923200094 RADIATOR 1

9-1 0602011079 RADIATOR CAP 1

9-2 M9200100904 PLUG 1

9-3 0150000016 O-RING 1

10 B1312600004 RUBBER MOUNT 2

11 0016908040 HEX HEAD BOLT 2

12 0207008000 HEX NUT 2

13 B1312500403 RADIATOR HOSE, UPPER 1

14 B1312500503 RADIATOR HOSE, LOWER 1

15 0605515149 HOSE BAND 4

16 M1310200003 FAN SHROUD 1

17 M1310200103 FAN SHROUD 1

17A M1493105004 ACCOUSTIC SHEET 1

18 0016908020 HEX HEAD BOLT 8

19 M1310300703 FAN GUARD 1

20 M1310300803 FAN GUARD 1

21 0016908020 HEX HEAD BOLT 8

22 0602046531 AIR CLEANER 1

22A 0602046611 AIR CLEANER ELEMENT 1

23 0602040690 AIR CLEANER INDICATOR 1

24 0602040552 AIR CLEANER BRACKET 1

25 0016908030 HEX HEAD BOLT 2

25A 0207008000 HEX NUT 2

26 M1373100303 AIR CLEANER HOSE 1

27 B1375100613 AIR CLEANER HOSE 1

28 0605515139 HOSE BAND 3

29 0602022560 ADAPTER 1

30 M1320300304 PACKING 1

31 0602022561 90 DEGREE ELBOW 1

32 0603306590 CONNECTOR 1

33 0603300285 ROCKNUT 1

34 0605511395 VALVE 1

35 0603306395 HOSE JOINT 1

36 0602021070 CAP 1

37 0269200280 DRAIN HOSE 1

PAGE 64 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 65

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY.REMARKS

38 1622014103 DRAIN JOINT 1

39 M9200200004 PLUG 1

40 0150000018 O-RING 1

41 0016906020 HEX HEAD BOLT 2

42 0199900600 DRAIN HOSE 1

43 0199900500 DRAIN HOSE 1

44 0605515106 HOSE BAND 4

45 0802081403 RESERVE TANK 1

46 0802081104 RESERVE TANK CAP 1

47 0199100205 HOSE 1

48 M1317100004 RESERVE TANK BRACKET 1

49 0199100350 HOSE 1

50 0193600850 HOSE 1

51 0605515106 HOSE BAND 2

52 0602120481 TACHOMETER PICK UP 1

53 0602122272 OIL PRESSURE UNIT 1

54 M9200100004 ADAPTER 1

55 0602123275 WATER TEMPERATURE UNIT 1

DCA-20SPX— ENGINE AND RADIATOR ASSY.

PAGE 66 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR

OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS

AFTER THE PART NUMBER WHEN ORDERING ANY

OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

MQGR - GRAY

MQGRN - GREEN

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 67

DCA-20SPX— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 B1231700303 TERMINAL PANEL 1

2 0840312704 OUTPUT TERMINAL BOLT 4

3 0801830604 TIE BOLT 4

4 0039308000 HEX BRASS NUT 8

5 0040008000 SPRING WASHER 12

6 0041408000 PLAIN WASHER 16

7 0016906020 HEX HEAD BOLT 4

8 M1236100313 TERMINAL COVER 1

9 M1236100404 OUTPUT WINDOW 1

10 0605010040 HINGE 2

11 0027103010 MACHINE SCREW 4

11A 0030003000 HEX HEAD NUT 4

11B 0041203000 PLAIN WASHER 4

12 0027103010 MACHINE SCREW 4

12A 0030003000 HEX HEAD NUT 4

13 0016906020 HEX HEAD BOLT 2

14 0016906015 HEX HEAD BOLT 4

15 8085182004 CABLE OUTLET COVER 1

16 8085183004 CABLE OUTLET COVER SUPPORTER 1

17 0016906020 HEX HEAD BOLT 6

18 0601870441 CIRCUIT BREAKER, 2P 50A 2

19 0601870440 CIRCUIT BREAKER, 1P 20A 2

20 M1260700404 BREAKER FITTING COVER 1

20-1 0222100080 RUBBER CUSHION 2

21 0016906020 HEX HEAD BOLT 2

22 0601812598 RECEPTACLE, 125V 20A (GF-530EM) 2

23 0601812565 RECEPTACLE, 250V 50A (CS6369) 2

24 0027104016 MACHINE SCREW 8

24A 0207004000 HEX NUT 8

25 M1236100503 TERMINAL COVER 1

26 0010112045 HEX HEAD BOLT 2

27 0041212000 PLAIN WASHER 2

28 0805009804 RUBBER STAY 2

29 0030012000 HEX NUT 2

30 0601815324 TERMINAL 1

31 0027104016 MACHINE SCREW 2

PAGE 68 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— BATTERY ASSY.

BATTERY ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 69

DCA-20SPX— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 0602220185 BATTERY 1

2 B9310500004 BATTERY SHEET 1

3 M9103000304 BATTERY BAND 1

4 0602220920 BATTERY BOLT SET 2

5 0030006000 SPRING WASHER 2

6 M1348400204 BATTERY CABLE 1

7 M2346400104 BATTERY CABLE 1

8 0017110025 HEX HEAD BOLT 3

9A 0040510000 TOOTHED WASHER 3

PAGE 70 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— MUFFLER ASSY.

MUFFLER ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 71

DCA-20SPX— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 B1330101403 MUFFLER 1

2 0016908020 HEX HEAD BOLT 4

3 M1333201703 EXHAUST PIPE 1

4 0602320100 GASKET 1

5 B1333200804 GASKET 1

6 0207008000 HEX NUT 4

7 0016908035 HEX HEAD BOLT 4

8 M1330400204 COVER 2

9 0016906015 HEX HEAD BOLT 4

PAGE 72 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— FUEL TANK ASSY.

FUEL TANK ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 73

DCA-20SPX— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 M1363000212 FUEL TANK 1

2 0605505070 FUEL TANK CAP 1

3 M1363200004 TANK BAND 2

4 0805003404 SUPPORTER SHEET 4

5 0016908020 HEX HEAD BOLT 2

6 0207308000 SUPER LOCK NUT 2

7 0222100080 RUBBER SHEET 4

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 8943672922 FUEL FILTER ................................................. 1 ......... REPLACES P/N 0602042202

14A 8943692993 FUEL FILTER CARTRIDGE ........................... 1 ......... REPLACES P/N 0602042700

15 M1366700104 FUEL FILTER BRACKET 1

16 0016908020 HEX HEAD BOLT 6

17 8970398340 FUEL PUMP ................................................... 1 ......... REPLACES P/N 0602023177

17A 8944370220 FUEL FILTER ................................................. 1 ......... REPLACES P/N 0602042425

18 0016906025 HEX HEAD BOLT 2

19 0191200900 SUCTION HOSE 1

20 0191200300 SUCTION HOSE 1

21 0191200650 SUCTION HOSE 1

22 0191201100 RETURN HOSE 1

23 0605515108 HOSE BAND 5

24 0605515064 HOSE BAND 3

PAGE 74 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— ENCLOSURE ASSY.

ENCLOSURE ASSY.

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR

OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS

AFTER THE PART NUMBER WHEN ORDERING ANY

OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

MQGR - GRAY

MQGRN - GREEN

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 75

DCA-20SPX— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 M1413002802 BASE 1

2 M1413400004 UNDER COVER 1

3 0016908020 HEX HEAD BOLT 2

4 M1423001802 FRONT FRAME 1

4A M1493104903 ACOUSTIC SHEET 1

5 0016908020 HEX HEAD BOLT 4

6 M1423200304 FRONT FRAME COVER 1

6A M1493100604 ACOUSTIC SHEET 1

7 0019208020 HEX HEAD BOLT 11

8 M1433000203 CENTER FRAME 1

9 M1433000303 CENTER FRAME 1

10 0010114030 HEX HEAD BOLT 8

10A 0040014000 SPRING WASHER 8

10B 0041214000 PLAIN WASHER 8

11 M1443001402 REAR FRAME 1

12 0016908020 HEX HEAD BOLT 4

13 M1443300513 REAR COVER 1

13A M1493300304 ACOUSTIC SHEET 1

14 M1443301503 REAR COVER DUCT 1

14A M1493300404 ACOUSTIC SHEET 1

15 0207006000 HEX NUT 7

16 0019208020 HEX HEAD BOLT 7

17 M1443200613 REAR DOOR 1

18 M1443600114 WINDOW PLATE 1

19 0037906000 U NUT 8

19A 0041206000 PLAIN WASHER 8

20 B9114000002 DOOR HANDLE ASSY. 1

21 0021806016 MACHINE SCREW 4

21A 0030006000 HEX HEAD NUT 4

22 0845047104 HINGE 2

23 0845045004 WASHER 2

24 0019208020 HEX HEAD BOLT 3

25 0845031504 BLIND PLUG 2

26 M1463001702 ROOF PANEL 1

26A M1493502903 ACOUSTIC SHEET 1

27 0019208020 HEX HEAD BOLT 18

28 1625165103 BONNET CAP 1

29 1625165204 CHAIN ASSY. 1

29-1 0016908020 HEX HEAD BOLT 1

30 B1454202602 SPLASHER PANEL 1

31 0019108055 HEX HEAD BOLT 2

31A 0042308000 SPRING WASHER 2

31B 0042408000 PLAIN WASHER 2

32 0016908020 HEX HEAD BOLT 2

PAGE 76 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

THE SERIAL NUMBER MAY BE REQUIRED.

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR

OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS

AFTER THE PART NUMBER WHEN ORDERING ANY

OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

MQGR - GRAY

MQGRN - GREEN

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 77

DCA-20SPX— ENCLOSURE ASSY. (CONT.)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY.REMARKS

33 M14530030803 SIDE DOOR 1

33A M1493405604 ACOUSTIC SHEET 1

34 M1453003903 SIDE DOOR 1

34A M1493405704 ACOUSTIC SHEET 1

35 M1453004003 SIDE DOOR 1

35A M1493405804 ACOUSTIC SHEET 1

36 M1453004103 SIDE DOOR 1

36A M1493405904 ACOUSTIC SHEET 1

37 M1453301403 DUCT 1

38 0207006000 HEX NUT 8

39 B9114000002 DOOR HANDLE ASSY. 3

40 0021806016 MACHINE SCREW 12

40A 0030006000 HEX HEAD NUT 12

41 0845047104 HINGE 4

42 0845047204 HINGE 4

43 0845045004 WASHER 8

44 0019208020 HEX HEAD BOLT 9

45 0601850097 DOOR STOPPER 8

46 0027208025 MACHINE SCREW 8

47 00845031504 BLIND PLUG 8

48 0600500090 EMBLEM 1

49 0021106015 MACHINE SCREW 2

50 0016910020 HEX HEAD BOLT 1

50A 0040510000 TOOTHED WASHER 1

51 0016908020 HEX HEAD BOLT 1

51A 0040508000 TOOTHED WASHER 1

52 0016906020 HEX HEAD BOLT 1

52A 0040506000 TOOTHED WASHER 1

PAGE 78 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 79

DCA-20SPX— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 0228901170 RUBBER SEAL 2

2 0228900695 RUBBER SEAL 3

3 0228900725 RUBBER SEAL 1

4 B1491300004 RUBBER SEAL 1

5 0228800325 RUBBER SEAL 1

6 0228900370 RUBBER SEAL 1

7 0228900550 RUBBER SEAL 1

8 0228900560 RUBBER SEAL 1

9 0229200595 RUBBER SEAL 1

10 0228900620 RUBBER SEAL 1

11 0229200750 RUBBER SEAL 2

12 0229200740 RUBBER SEAL 1

13 0228800670 RUBBER SEAL 2

14 0228800445 RUBBER SEAL 1

15 0228800485 RUBBER SEAL 1

16 0228100458 RUBBER SEAL 1

17 0228100171 RUBBER SEAL 1

18 0228100351 RUBBER SEAL 1

19 0228100285 RUBBER SEAL 1

20 0228100153 RUBBER SEAL 1

21 0228100180 RUBBER SEAL 1

PAGE 80 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

DCA-20SPX— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 81

DCA-20SPX— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY.REMARKS

1 B1551003203 DECAL : GENERATOR CONTROL .................................. 1 ........... B15100320

2 B1551003303 DECAL : ENGINE OPERATING ...................................... 1 ........... B15100330

3 M1550001803 DECAL : AUXILLARY OUTPUT ....................................... 1 ........... M15000180

4 M1550001904 DECAL : CAUTION : LIFTING CAP ................................. 1 ........... M15000190

5 6360620204 DECAL : OIL DRAIN PLUG ............................................. 1 ........... S-1885

6 6360610304 DECAL : WATER .............................................................. 1 ........... S-1880

7 6360620104 DECAL : WATER DRAIN .................................................. 1 ........... S-1884

8 W0800689504 DECAL : - ........................................................................ 1 ........... S-2091

9 W0800689404 DECAL : + ....................................................................... 1 ........... S-2090

10 1320620904 DECAL : DIESEL FUEL .................................................. 1 ........... S-1756

11 6360620004 DECAL : FUEL DRAIN PLUG .......................................... 1 ........... S-1883

12 B9504000404 DECAL : WARNING : POTATING PART. .......................... 2 ........... B90400040

13 1320610603 DECAL : WATER * OIL CHECK ....................................... 1 ........... S-1760

14 B9504100104 DECAL : WARNING : RADIATOR CAP ............................ 1 ........... B90410010

15 B9504200004 DECAL : WARNING : EXHAUST GAS............................. 1 ........... B90420000

16 B9504000304 DECAL : CAUTION .......................................................... 1 ........... B90400030

17 0840625902 DECAL : MQ .................................................................... 1 ........... S-3057

18 0840614104 DECAL : GROUND .......................................................... 1 ........... S-2635

19 0840505604 DECAL : AMMETER CHANGE-OVER SWITCH ............. 1 ........... N-4590

20 B9531100604 DECAL : WARNING : ELECTRICAL SHOCK ................... 2 ........... B93110060

21 M9520100503 DECAL : WARNING ......................................................... 1 ........... M92010050

22 B9521100404 DECAL : SAFETY INSTRUCTIONS ................................ 1 ........... B92110040

23 M9520100404 DECAL : DANGER : HIGH VOLTAGE .............................. 1 ........... M92010040

24 M1560100403 STRIPE : WHISPERWATT 1

25 B1561101604 STRIPE : 20 2

26 M1560101604 DECAL : MQ POWER 2

27 M1560101704 STRIPE 2

28 M1560101804 STRIPE 2

29 M9521000004 DECAL : TERMINAL ........................................................ 1 ........... M92100000

30 C9522100003 CAUTION ......................................................................... 2 ........... C92210000

31 B2551000403 DECAL : HANDLING PROCEDURES ............................. 1 ........... B25100040

32 9039209064 START CONTACT ........................................................... 1 ........... S-4468

33 A9504000004 DECAL : WARNING : EXHAUST GAS ............................. 1 ........... A90400000

PAGE 82 — DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10)

TERMS AND CONDITIONS OF SALE — PARTS

Effective: February 22, 2006

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or

prepaid with the charges added to the invoice.

All shipments are F.O.B. point of origin.

Multiquip’s responsibility ceases when a

signed manifest has been obtained from the

carrier, and any claim for shortage or damage

must be settled between the consignee and

the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip

is $15.00 net. Customers will be asked for

instructions regarding handling of orders not

meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and

credit will be allowed, subject to the following

provisions:

A Returned Material Authorization 1.

must be approved by Multiquip prior to

shipment.

To obtain a Return Material Authorization, 2.

a list must be provided to Multiquip

Parts Sales that deﬁnes item numbers,

quantities, and descriptions of the items

to be returned.

The parts numbers and descriptions a.

must match the current parts price

list.

The list must be typed or computer b.

generated.

The list must state the reason(s) c.

for the return.

The list must reference the sales d.

order(s) or invoice(s) under

which the items were originally

purchased.

The list must include the name e.

and phone number of the person

requesting the RMA.

A copy of the Return Material Authorization 3.

must accompany the return shipment.

Freight is at the sender’s expense. All 4.

parts must be returned freight prepaid to

Multiquip’s designated receiving point.

Parts must be in new and resalable 5.

condition, in the original Multiquip

package (if any), and with Multiquip part

numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a.

price book and shows as being

replaced by another item, it is

obsolete.)

Any parts with a limited shelf life b.

(such as gaskets, seals, “O” rings,

and other rubber parts) that were

purchased more than six months

prior to the return date.

Any line item with an extended c.

dealer net price of less than

$5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper 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

instructions. If a reply is not received

within five days, the material will be

returned to the sender at his expense.

Credit on returned parts will be issued 9.

at dealer net price at time of the original

purchase, less a 15% restocking

charge.

In cases where an item is accepted, for 10.

which the original purchase document

can not be determined, the price will be

based on the list price that was effective

twelve months prior to the RMA date.

Credit issued will be applied to future 11.

purchases only.

PRICING AND REBATES

Prices are subject to change without prior

notice. Price changes are effective on a

speciﬁc date and all orders received on or

after that date will be billed at the revised price.

Rebates for price declines and added charges

for price increases will not be made for stock

on hand at the time of any price change.

Multiquip reserves the right to quote and

sell direct to Government agencies, and to

Original Equipment Manufacturer accounts

who use our products as integral parts of their

own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the

invoice for special handling including bus

shipments, insured parcel post or in cases

where Multiquip must personally deliver the

parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder fo

damages in excess of the purchase price of

the item with respect to which damages are

claimed, and in no event shall Multiquip be

liable for loss of proﬁt or good will or for any

other special, consequential or incidental

damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are

made in connection with the sale of parts or

trade accessories nor as to any engine not

manufactured by Multiquip. Such warranties

made in connection with the sale of new,

complete units are made exclusively by a

statement of warranty packaged with such

units, and Multiquip neither assumes nor

authorizes any person to assume for it

any other obligation or liability whatever in

connection with the sale of its products. Apart

from such written statement of warranty,

there are no warranties, express, implied or

statutory, which extend beyond the description

of the products on the face hereof.

Effective: February 22, 2006

DCA-20SPX— OPERATION AND PARTS MANUAL — REV. #2 (04/14/10) — PAGE 83

NOTE PAGE

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Your Local Dealer is:

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the

property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references 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 information published

in this publication at any time without notice and without incurring any obligations.

Further, MQ Power disclaims any warranties or guaranties, expressed or implied, with regards to the information contained in this manual. Manufactured for

Multiquip Inc.

DENYO CO., LTD, JAPAN

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave Tel. (800) 421-1244

Carson, CA 90746 Fax (800) 537- 3927

Contact: mq@multiquip.com

Web: www.multiquip.com

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551

Suite 500/600 Fax (972) 315-1847

Lewisville, TX 75057

Contact: mqpower@multiquip.com

Web: www.mqpower.com

MQ Parts Department

800-427-1244 Fax: 800-672-7877

310-537-3700 Fax: 310-637-3284

Service/Tech Support/Warranty

800-835-2551 Fax: 310-638-8046

Multiquip Whisperwatt Series Dca 20Spx Users Manual Rev 2

WHISPERWATT SERIES DCA-20SPX Generators_portable_whisperwatt_DCA20SPX_rev_2_manual_DataId_19093_Version_1

DCA-20SPX to the manual c3c6443c-5477-4f15-adf4-6eb692bc734b

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