MQ Power WHISPERWATT DCA-36SPX Guide

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
Revision #0 (02/12/09)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
WHISPERWATTTM SERIES
MODEL DCA-36SPX
60 Hz GENERATOR
(PARTS LIST NO. B2871300404 S/N 3798495~)

PAGE 2 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)
Diesel engine exhaust and some of
PROPOSITION 65 WARNING

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 3
1
NOTE PAGE

PAGE 4 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)
TABLE OF CONTENTS
Specification and part
number are subject to
change without notice.
NOTE
MQ POWER DCA-36SPXMQ POWER DCA-36SPX
MQ POWER DCA-36SPXMQ POWER DCA-36SPX
MQ POWER DCA-36SPX
WHISPERWHISPER
WHISPERWHISPER
WHISPERWW
WW
WAA
AA
ATTTT
TTTT
TTTMTM
TMTM
TM
GENERATORGENERATOR
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
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 ............................ 82
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS

DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 5
1
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:
❒❒
❒❒
❒ Dealer Account Number
❒❒
❒❒
❒ Dealer Name and Address
❒❒
❒❒
❒ Shipping Address (if different than billing address)
❒❒
❒❒
❒ Return Fax Number
❒❒
❒❒
❒ Applicable Model Number
❒❒
❒❒
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓DHL
■
Priority One ✓ Tr uck
■ Ground
■Next Day
Allordersaretreatedas StandardOrders
andwillshipthesameday if receivedprior
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
[email protected].
To obtain an MQ Account, contact your
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
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
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
Order via Phone: Domestic (US) Dealers Call:
International Customers should con-
tact their local Multiquip Representatives
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
Note: Discounts Are Subject To Change
Effective:

PAGE 6 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)
DCA-36SPX — SPECIFICATIONS
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DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 7
1
DCA-36SPX — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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FRONT VIEW
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TOP VIEW
SIDE VIEW
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PAGE 8 — DCA-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)
This Owner's Manual has been
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power Model DCA-36SPX
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-36SPX — 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-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09) — PAGE 9
1
DCA-36SPX — 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-36SPX— OPERATION AND PARTS MANUAL — REV. #0 (02/12/09)
DCA-36SPX — RULES FOR SAFE OPERATION
The following safety guidelines should always be used when
operating the DCA-36SPXWhisperwatt™ 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
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