MULTIQUIP Power WHISPERWATT DCA-56SPX Leitfaden

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

Revision #1 (04/14/10)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALLTIMES.

WHISPERWATTTM SERIES

MODEL DCA-56SPX

60 Hz GENERATOR

(PARTS LIST NO. B4871301604 S/N 3796699~)

PAGE 2 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)

Diesel engine exhaust and some of

PROPOSITION 65 WARNING

DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 3

NOTE PAGE

PAGE 4 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)

TABLE OF CONTENTS

Specification and part

number are subject to

change without notice.

NOTE

MQ POWER DCA-56SPXMQ POWER DCA-56SPX

MQ POWER DCA-56SPX

WHISPERWHISPER

WHISPERWW

WAA

ATTTT

TTTT

TTTMTM

TMTM

GENERATORGENERATOR

GENERATOR

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

Here's How To Get Help .................................................... 3

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

Control Box Assembly ............................................... 58-59

Engine and Radiator Assembly ................................. 60-65

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

Actuaror Assembly .................................................... 68-69

Battery Assembly ...................................................... 70-71

Muffler Assembly ...................................................... 72-73

Fuel Tank Assembly .................................................. 74-75

Enclosure Assembly ................................................. 76-79

Rubber Seals Assembly ............................................ 80-81

Nameplate and Decals .............................................. 82-83

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (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:

RDealer Account Number

RDealer Name and Address

RShipping Address (if different than billing address)

RReturn Fax Number

RApplicable Model Number

RQuantity, Part Number and Description of Each Part

RSpecify Preferred Method of Shipment:

UPS/Fed ExDHL

NPriority OneTruck 

NGround

NNext Day

NSecond/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!

NView Parts Diagrams

NOrder Parts

NPrint 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)

DCA-56SPX — SPECIFICATIONS

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DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 7

DCA-56SPX — DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

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PAGE 8 — DCA-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)

This Owner's Manual has been

developed to provide complete

instructions for the safe and

efficient operation of the

MQ Power

Model DCA-56SPX

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-56SPX — 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 9

DCA-56SPX — 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-56SPX— OPERATION AND PARTS MANUAL — REV. #1 (04/22/10)

DCA-56SPX — RULES FOR SAFE OPERATION

The following safety guidelines should always be used when

operating the

DCA-56SPXWhisperwatt™ 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 generators 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

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