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Multiquip DCA-600SSV Portable Generator User Manual

1. DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 107 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Tel 800 421 1244 MQ Parts Department 800 427 1244 Fax 800 672 7877 Carson CA 90746 Fax 800 537 3927 310 537 3700 Fax 310 637 3284 Contact mq amp multiquip com Mayco Parts Warranty Department 800 306 2926 Fax 800 672 7877 800 421 1244 Ext 279 Fax 310 537 1173 310 537 3700 Fax 310 637 3284 310 537 3700 Ext 279 Service Department Technical Assistance 800 421 1244 Fax 310 537 4259 800 478 1244 Fax 310 631 5032 310 537 3700 MEXICO UNITED KINGDOM MQ Cipsa Multiquip UK Limited Head Office Tel 0161 339 2223 Fax 0161 339 3226 Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Hanover Mill Fitzroy Street Ashton under Lyne Tel 52 222 225 9900 Fax 52 222 285 0420 Contact pmastretta cipsa com mx Lancashire OL7 OTL Contact sales multiquip co uk CANADA BRAZIL Multiquip Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin amp multiquip com Tel 450 625 2244 Fax 450 625 8664 Av Evandro Lins e Silva 840 grupo 505 Tel 011 55 21 3433 9055 Barra de Tijuca Rio de Janeiro Fax 011 55 21 3433 90
2. HEX HEAD BOLT SPRING WASHER SET PLATE RECTIFIER RECTIFIER HEX SOCKET SHCS SPRING WASHER PLAIN WASHER HEAD HEX BOLT WASHER LOCK BALANCING WEIGHT KIT BEARING FLANGE BEARING SNAP RING HEX HEAD BOLT WASHER LOCK STATOR ASSY CLAMPER CLAMPER CLAMPER HEX HEAD BOLT HEX NUT WASHER LOCK WASHER FLAT HEX HEAD BOLT END BRACKET FIELD ASSY EXCITER HEX HEAD BOLT WASHER LOCK WASHER FLAT GROMMET HEX HEAD BOLT WASHER LOCK WASHER FLAT QTY DCA 600SSV GENERATOR ASSY REMARKS O O O C R OO O gt NP NOT SOLD SEPARETLY PURCHASE ITEM 1 17 AS A SET DCA 600SSV GENERATOR ASSY GENERATOR ASSY PAGE 66 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 GENERATOR ASSY NO 9 7431310003 10 8461312004 11 0016308095 0040008000 11B 0041208000 12 0010110016 13 0803000104 14 8461335003 15 8461334003 16 0017106012 17 0017106050 18 8461333003 19 0017106012 20 0343206170 20A 0043606000 21 8461332003 22 0017106050 23 0605000012 24 0030020000 24A 0040020000 25 C3164701404 26 0070506208 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 67 DCA 600SSV GENERATOR ASSY PART NAME COVER BEARING GASKET BEARING HEX HEAD BOLT SPRING WASHER PLA
3. 74 0605010502 75 8481814503 76 0017108020 77 C4214300904 78 0601850349 79 C4214301004 80 0017108020 81 C4214400404 82 8481825304 83 0017108020 84 0017110030 85 0017108020 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 73 DCA 600SSV PART NAME SNAP PIN COVER CONTROL BOX HEX HEAD BOLT SIDE PANEL CONTROL BOX EMBEDDED PULLS SIDE PANEL CONTROL BOX HEX HEAD BOLT PANEL CONTROL BOX PANEL CONTROL BOX HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT CONTROL BOX ASSY CONT QTY REMARKS DCA 600SSV ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY 4 53646 44 r 35 36464 m Lai 2423 2622 28 VIEW Y PAGE 74 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSY NO PART NAME QTY REMARKS 1 4924200284 ENGINE 8 RADIATOR SET TAD1642GE 1A 0602015240 BELT FAN 1 1B 0602015241 BELT ALTERNATOR 1 1 1 0602046623 ELEMENT AIR CLEANER 1 1 2 0602041278 CARTRIDGE OIL FILTER FULL FLOW 2 1 3 0602041276 CARTRIDGE OIL FILTER BY PASS 1 1 4 0602042562 CARTRIDGE FUEL FILTER 1 1 5 0602042768 CARTRIDGE FUEL FILTER PRE FILTER 1 1 6 0602045161 CARTRIDGE CORROSION RESISTOR 1 C4304200804 ENGINE FOOT C4304200704 ENGINE FOOT C
4. OIL FILTER ECON 6004111030 CARTRIDGE CORROSION RESISTOR 0601810575 PILOT LAMP ENGINE TROUBLE pom 0601810576 PILOT LAMP ENGINE TROUBLE 0412222568 ENGINE FAN BELT ___ 6008155390 SWITCH STARTER UP TO S N 3698616 _ KEY SET STARTER SWITCH 2 UP S N 3698616 A 0602122281 OIL SWITCH 6995621691 RADIATOR HOSE UPPER LE 6162639650 RADIATOR HOSE LOWER 0605505030 FUEL CAP 06018206425 AUTOMATIC VOLTAGE REGULATOR gt 0601805313 CIRCUIT BREAKER 265V 20A 6 0601805840 CIRCUIT BREAKER 265V 50A i 0601802525 HANDLE MAIN CURRENT BREAKER 0601840073 VOLTAGE REGULATOR RHEOSTAT P onini 0601840121 KNOB VOLTAGE REGULATOR EN 0601810072 PILOT LAMP 0601810261 BULB PILOT LAMP 23S0311150M CAP RADIATOR 0602122203 UNIT OIL PRESSURE Jogo 0602123206 UNIT WATER TEMPERATURE 0602121052 CHARGING AMMETER _ ECU9988N600 800 ECU ENGINE CONTROLLER S N 3698617 Part number on this Suggeste
5. 847256 DRAIN PLUG P N 1320620904 P N 6360620004 Figure 3 Generator Decals DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 17 DCA 600SSV INSTALLATION GENERATOR GROUND LUG SWZ GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND 8 FT MINIMUM REFERENCE NEC 250 52 C Figure 4 Typical Generator Grounding Application PAGE 18 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV INSTALLATION 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 AX CAUTION EXHAUST HAZARD 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 Indoor Ins
6. Figure 15 Voltage Change Over Board 240V 3 Configuration AC Voltmeter Gauge Reading Place the AC Voltmeter Change Over Switch Figure 16 in the W U position and observe the phase to phase voltage reading between the W and U terminals as indicated in the AC Voltmeter Gauge Figure 17 V W U V W U OFF Figure 16 AC Voltmeter Change Over Switch Figure 17 AC Voltmeter Gauge Volt reading on W U Lug AC Ammeter Gauge Reading Place the AC Ammeter Change Over Switch Figure 18 inthe U position and observe the current reading load drain on the U terminal as indicated in the AC Ammeter Gauge Figure 19 This process can be repeated for terminals V and W V Figure 18 AC Ammeter Change Over Switch Figure 19 AC Ammeter Amp reading on U lug The ammeter and voltmeter gauges will only show a reading when the Output Terminal Lugs are connected to a load and in use DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 31 DCA 600SSV OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO output terminal lugs The voltages at the terminals are de pendent on the placement of the jumpers plates 6 on the Voltage Change Over Board and the adjustment of the Voltage Regulator Control Knob Remember the voltage change over board determines the range of the output voltage and can be configured in two differen
7. MAIN CIRCUIT BREAKER OFF LAMP Figure 41 Main Circuit Breaker OFF Lamp Place the G F C L and aux circuit breakers Figure 42 in the OFF position prior to starting the engine CIRCUIT BREAKERS FOR GFCI RECEPTACLES alld MM CIRCUIT BREAKERS FOR 6369 TWIST LOCK RECEPTACLES Figure 42 GFCI and Auxiliary Circuit Breakers OFF 4 Connect the load to the UVWO terminals or auxiliary receptacles as shown in Figure 43 These load connection points can be found on the output terminal panel To gain access to the UVWO terminals or other power receptacles unlock the access cover and lift the door 5 Tighten the UVWO terminal nuts securely to prevent load wires from slipping out VOLTAGE OUTPUT TMISTLOCK TERMINALS RECEPTACLES Figure 43 Load Connections 6 Close all engine enclosure doors Figure 44 INCORRECT Figure 44 Engine Enclosure Doors DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 39 DCA 600SSV GENERATOR START UP PROCEDURE MANUAL 7 Setthe battery ON OFF switch Figure 45 to the ON position OFF Figure 45 Battery ON OFF Switch 8 Press and hold the engine preheat button Figure 46 until the 6 lamp is lit ON Pre Heat Button Figure 46 Pre Heat Button Lamp Pre Heat 7 Lamp 9 Place the engine speed switch in the LOW position Figure 47 HIGH UP LOW DOWN Figure 47 Engine Speed Switch L
8. before disengaging AUTO 6 MANUAL During cranking cycle The MPEC will attempt to crank the engine for 10 seconds before disengaging Ifthe 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 MPEC will shutdown the generator 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 MPEC module A Off Manual Auto Switch This switch controls the running of the generator If this switch is left in the OFF position the generator 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 Low Oil Pressure Indi
9. A R MAKE LOCALLY 4 12349 BEARING 1 SIN2345B AND ABOVE NO Column Unique Symbols All items with same unique symbol or gt in the number column belong to the same assembly or kit which is indicated by a note inthe Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers 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 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 PART NO Column Numbers Used Part numbers can be indicated by a number ablank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at 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 QTY Column Numbers Used quantity can be indicated by a number a blank entry or 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 Col
10. Figure 35 Filling Secondary Internal Fuel Tank 5 Figure 36 below reflects a full fuel system FILL 3 4 FULL DO NOT TOP OFF FUEL GAUGE LOCATED ON CONTROL PANEL LI LMA MLA a MLA Mc tt 222222222 Figure 36 Full Fuel System 6 Fuel from the engine return line will drain into the secondary internal fuel tank This fuel will eventually drain into the primary trailer tank in order to return to the engine Ay CAUTION REFUELING SECONDARY FUEL TANK It is recommended to only fill the internal secondary take to 3 4 full in order to allow for fuel return fuel expansion and to avoid spillage See Figure 37 for fuel expansion Fuel EXPANDS When Heated Figure 37 Fuel Expansion PAGE 36 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV SETUP Coolant Ethylane Glycol Green Water 50 50 mix Use only drinkable tap water If hard water or water with many impurities is used the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system See the engine manual for further details AX WARNING BURN HAZARDS If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled The can cause severe burns Day to day addition of coolant is done fr
11. Low coolant level Fill coolant level oe evel light Sending unit failure Replace sending unit Low battery voltage Replace charge battery Fan belt tension incorrect Tighten replace fan belt Air flow is not circulation through radiator Clean repair radiator grill High coolant Exhaust leaking Replace repair gaskets or faulty part temperture light iS Generator being overloaded Check reduce load Thermostat failure Replace thermostat Air intake blocked Clear all air intakes Temperature switch failure Replace temperature switch No or low Fuel Fill fuel level Overcrank light is on Controller needs to be calibrated Refer to dealer RPM engine speed too high Adjust RPM Governor actuator needs to be adjusted Adjust governor actuator Overspeed light is on Governor controller needs to be adjusted Adjust governor controller Engine Controller needs to be calibrated Refer to dealer Loss of MPU light s or Magnetic pick up out of adjustment Adjust magnetic pick up om Magnetic pick up dirty Clean magnetic pick up DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 59 DCA 600SSV TROUBLESHOOTING DIAGNOSTIC LAMP The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself The malfunction can be determined by examining the flashing pattern of the diagnostic lamp Figure 79 located in the control box DIAGNOST
12. Generator Wiring 53 Generator Wiring Diagram Main Breaker 54 Engine Wiring Diagram 55 56 Engine Troubleshooting 57 58 Generator Troubleshooting 59 Engine Contoller Troubleshooting 60 Troubleshooting Diagnostic Lamp 61 Explanation of Codes in Remarks Column 62 Suggested Spare Parts 63 COMPONENT DRAWINGS Generator Assembly 64 67 Control Box 68 73 Engine Radiator Assembly 74 77 Engine Operating Panel Assembly 78 79 Output Terminal Assembly 80 83 Battery Assembly 84 85 Muffler Assembly 22 1 86 87 Fuel Tank Assembly aaa AE 88 89 Enclosure 1 90 93 Enclosure 2 Assembly 94 97 Enclosure 3 Assembly 98 99 Enclosure Rubber Seals 100 101 Nameplate and Decals 102 105 Terms and Conditions Of Sale Parts 106 Specification and part number
13. SIDE PANEL ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET SIDE DOOR ACOUSTIC SHEET LOUVER PANEL LOUVER PANEL HEX NUT DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET DUCT ACOUSTIC SHEET HEX NUT DOOR HANDLE DOOR HANDLE MACHINE SCREW HINGE WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW HEX HEAD BOLT CAP DCA 600SSV ENCLOSURE 3 ASSY QTY REMARKS n2 266 DCA 600SSV RUBBER SEAL ASSY RUBBER SEAL ASSY PAGE 100 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 RUBBER SEAL ASSY NO 1 0229201650 2 0228901440 3 0228901670 4 0228901020 5 0228901610 6 0228900960 7 0228801610 8 0228800860 9 0228801380 10 0229201490 11 0229200780 12 0229200595 13 0228100500 14 0228100270 15 0228100580 16 0228100140 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 101 PART NAME RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL QTY DCA 600SSV RUBBER SEAL ASSY REMARKS 2 8 4 2 3 1 2 2 2 2 2 2 2 2 2 2 DCA 600SSV NAM
14. positive RED m w Mm M oou BATTERY Figure 39 Battery Connections When connecting battery do the following 1 NEVER connect the battery cables to the battery terminals when the ignition switch is in either the Pre Heat RUN or START position ALWAYS make sure that the ignition switch is in the STOP 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 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 CAUTION BATTERY SERVICING SAFETY 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 leads an electrolyte corrosion causing an alternator failure Before charging the battery with an external electric source be sure to disconnect the battery cables Wiring Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or conn
15. v DHL CJ Shipping Address if different than billing address dai One v Truck C Return Fax Number Next Day Applicable Model Number Allorders are treated as Standard Orders andwillship the same day if received prior VAY WE ACCEPT ALL MAJOR CREDIT CARDS DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 5 DCA 600SSV SPECIFICATIONS Table 1 Generator Specifications open protected type synchronous generator Pse lw Table 2 Engine Specifications VOLVO PENTA TAD1642GE G sm 33 1 gal 125 2 L hr at full load 24 2 gal 91 7 L hr at 3 4 load Fuel Consumption 17 3 gal 65 4 L hr at 1 2 load 10 5 gal 39 6 L hr at 1 4 load PAGE 6 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV DIMENSIONS TOP SIDE AND FRONT TOP VIEW b S oy SES Figure 1 Dimensions _MQPOWER POWER SIDE VIEW TABLE 3 DIMENSIONS E 7 8 mensem mamam mnnm 72 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 7 DCA 600SSV SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY ANDTHE SAFETY OF OTHERS Safety precautions should be followed at all times when operating t
16. 12A 0042312000 SPRING WASHER 6 128 0042412000 PLAIN WASHER 6 13 0601850275 GROMMET 1 14 0601815324 TERMINAL BOARD 1 15 0027104020 MACHINE SCREW 2 16 C4237101304 COVER OUTPUT TERMINAL 1 17 7971867114 RUBBER SHEET 1 18 7521865804 SET PLATE RUBBER SHEET 2 19 0019106020 HEX HEAD BOLT 5 19A 0042306000 SPRING WASHER 5 19B 0042406000 PLAIN WASHER 5 20 0605010660 KNOB 2 21 0207006000 HEX NUT 2 22 0019112040 HEX HEAD BOLT 4 23 0042412000 PLAIN WASHER 8 24 0805009804 STAY RUBBER 4 25 0030012000 HEX NUT 4 26 7521865603 STOPPER 1 27 0019108030 HEAD BOLT 1 27A 0030008000 1 278 0041208000 PLAIN WASHER 2 28 C4237100504 COVER 1 29 0017108020 HEAD BOLT 5 30 0601808803 CIRCUIT BREAKER 20A 2 31 0601808804 CIRCUIT BREAKER 50A 3 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 81 DCA 600SSV OUTPUT TERMINAL ASSY CONT OUTPUT TERMINAL ASSY ELF PAGE 82 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV OUTPUT TERMINAL ASSY CONT OUTPUT TERMINAL ASSY NO PART NAME QTY REMARKS 32 C3261600704 BRACKET CIRCUIT BREAKER 1 32 1 0221200150 RUBBER CUSHION 1 33 0017106030 HEX HEAD BOLT 2 34 0601812598 RECEPTACLE 2 35 0601812565 RECEPTACLE 3 36 0027104015 MACHINE SCREW 10 0030004000 HEX NUT 10 36B 0041204000 PLAIN WASHER 10 37 C4237101203 COVER 1 38 06061851780 GROM
17. 19 0019208025 20 4331400204 21 0019210020 22 0603320132 23 0207310000 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 87 PART NAME MUFFLER HEX HEAD BOLT PACKING PACKING HEX HEAD BOLT HEX HEAD BOLT EXHAUST PIPE EXHAUST PIPE SEAL CLAMP GASKET HEX HEAD BOLT SPRING WASHER PLAIN WASHER COVER HEX HEAD BOLT HEX HEAD BOLT OUTLET PIPE GASKET HEX HEAD BOLT HEX NUT SPRING WASHER PLAIN WASHER COVER HEX HEAD BOLT BRACKET HEX HEAD BOLT U BOLT HEX NUT QTY DCA 600SSV MUFFLER ASSY REMARKS 1 4 2 2 0 6 1 1 1 1 8 8 8 1 2 4 1 1 4 4 4 8 1 4 1 2 1 2 DCA 600SSV FUELTANK ASSY FUEL TANK ASSY zE PAGE 88 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 FUEL TANK ASSY NO 1 C4364002203 1 1 0845500104 1 2 0810105400 1 3 0264100505 1 4 0605515079 2 0605503023 3 0802120604 4 C2924300034 5 E1924300184 6 0022905015 7 8225523104 8 0805003414 9 0017108020 10 0207308000 11 0222100600 12 0130206000 13 0134306220 14 0603325026 15 0132006000 16 C1367700304 17 0019208025 18 0845039604 19 C4367200004 20 0603303071 21 0603302071 22 0191403400 23 0191403800 24 0605515073 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 89 PART NAME FUEL TANK CAP FUEL TANK FUEL FILTER HOSE FUEL GAUGE HOSE BAND FUEL SENSOR
18. PACKING FUEL SENDER GASKET MACHINE SCREW TANK BAND PAD TANK BAND HEX HEAD BOLT SELF LOCKING NUT TANK SHEET STREET ELBOW 1 2 DRAIN PIPE VALVE PLUG LOCK PLATE HEX HEAD BOLT RUBBER SEAL JOINT PIPE NUT SLEEVE SUCTION HOSE RETURN HOSE HOSE BANK QTY DCA 600SSV FUELTANK ASSY REMARKS 1 1 1 1 2 1 1 1 1 5 2 4 2 2 6 1 1 1 1 1 2 1 2 2 2 1 1 4 ASSY ENCLOSURE 1 gt o co DCA a gt 5 R RE gt LLI lt 2 lt CD lt a lt o lt a gt CD 72 2 lt O a LLI lt ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY NO 1 C4414003302 2 3875116304 3 0019208020 4 C4414100204 5 C4414100304 6 7 8 C4414100404 0019208020 C4414400104 9 0019208020 10 C4414200003 10 C4494000004 10 1 0314500110 11 0019208020 12 C4414600504 13 C4414600604 14 0017108020 15 C4424005003 15 C4494102803 16 C4424005303 16A C4494102803 17 C4424005502 17A C4494102803 18 C4424005402 18A C4494102803 19 0019208020 20 C4424300903 20A 4494102803 21 C4424301003 21A C4494102803 22 0019208020 23 0019210025 24 C4424204803 25 C4424204704 25A C4494102204 26 0019208020 27 0845042703 28 0019208020 29 C4424204604 30 0019206016 31 C4424206703 32 0019208020 33 C4434001402 34 0010120065 34A 0030020000
19. TABLE 19 TRAILER WIRE DIAGRAM POLE DESCRIPTION COLOR LEFT TURN YELLOW EARTH _______ RIGHT TURN GREEN 5 582 SERVICE BRAKES BLUE STOP LAMP RED BROWN Figure 73 Trailer Wiring Diagram 7 Pin PAGE 52 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR WIRING DIAGRAM 0 u v w CONTROL BOX CONTROL PANEL BRUSHLESS AG GENERATOR Figure 74 Generator Wiring Diagram AVR CONNECTOR NAME MAIN GENERATOR ARMATURE WINDING CONTROL BOX SIDE AS AMMETER CHANGE OVER SWITCH ACAMMETER 0 400 800A Hiv VOLTMETER CHANGE OVER SWITCH VIEW FROM INSERTING AC VOLTMETER 0 600V WIRE SIDE FREQUENCY METER 45 65HZ PILOT LAMP CB2 3 AUX CIRCUIT BREAKER 20A 4 6 AUX CIRCUIT BREAKER 50A SYM WIRE COLOR CONT 2 AUX POWER RECEPTACLE 20A CON3 5 AUX POWER RECEPTACLE 50A PANEL LIGHT SW PANEL LIGHT SWITCH e emm ORANGE D DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 53 DCA 600SSV GENERATOR WIRING DIAGRAM MAIN BREAKER REFERENCE GENERATOR CONNECTION DIAGRAM CIRCUIT ol BREAKER C13 4 6 PL5 TRES ON OFF R RELAY CONNECTOR CONTROL BOX SIDE VIEWED FROM INSERTING WIRE SIDE CONTROL PANEL SIDE WIRE SIZE COLOR CODE CODE WIRE COLOR 5 gt 125 125 BLACK 100 100 BLUE CIRCUIT BREAKE
20. Terminal Lugs 30 480V Connections ALWAYS make sure that the connections to the UVWO terminals are secure and tight 5 SINGLE PHASE The possibility of arcing exists that could cause a fire Figure 28 UVWO Terminal Lugs 10 277V Connections DANGER UVWO OUTPUT TERMINALS NEVER attempt to connect a load to the UVWO output terminals while the generator is operating The possibility exists of serious injury electrical shock electrocution even death DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 33 DCA 600SSV SETUP Fuel Check AX DANGER EXPLOSION FIRE HAZARDS Circuit Breakers To protect the generator from an overload a 3 pole 1600 amp main circuit breaker is provided to protect the UVWO output terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 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 Also verify that the oil level is maintained between the two notches Figure 29 on the dipstick See Table 9 for proper selection of engine oil ADD Figure 29 Engine Oil Dipstick When
21. The ammeter will only display a current 1 Perform steps 1 through 4 inthe Before Starting section page 38 as outlined in the Manual Starting Procedure Setthe battery ON OFF switch Figure 62 to the ON position Figure 62 Battery ON OFF Switch When the generator is set in the AUTO mode the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch Set the engine speed switch Figure 63 to the High position 4 HIGH UP Figure 63 Engine Speed Switch High Place the Off Manual Auto switch Figure 64 on the MPEC unit to the AUTO position lt AUTO MANUAL OFF RESET Figure 64 Off Manual Auto Switch AUTO Press the circuit breaker ON Switch Figure 58 Verify that the circuit breaker on lamp Figure 59 is lit Continue operating the generator as outlined in the Manual Start up procedure start at step 10 PAGE 42 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR SHUT DOWN PROCEDURE TR _ Shutdown Procedure 1 PUSH inward the emergency stop button located on the NEVER stop the engine suddenly except in an emergency engine operating panel Figure 67 to turn off the generator in the event of an emergency Normal Shutdown Procedure To shutdown the generator use the followin
22. applies to your type of fuel tank system ALWAYS fill the fuel tank with clean and 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 Generator Internal Fuel Tank EJ Trailer Fuel Tank Figure 30 Double Fuel Tank System PAGE 34 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 600 SETUP AX CAUTION TRAILER FUEL TANK ALWAYS fill trailer tank first with 2 diesel fuel before filling secondary internal tank INTERNAL lt SECONDARY TANK INTERNAL FUEL TANK Figure 31 Skid Type Fuel Tank System INCORRECT Refueling Procedure ALWAYS FILL THE Diesel fuel and its vapors are dangerous HEST BEFORE EIN ING to your health and the surrounding 8 INTERNAL FUEL TANK environment Avoid skin contact and or inhaling fumes 1 LevelTanks 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 See Figure 32 g pacity g TRAER CORRECT TANK A CAUTION REFUELING THE GENERATOR Figure 33 Fuel Tank Filling Order ALWAYS place trailer on firm level ground before
23. are subject to change without notice PAGE 4 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Effective Order via Internet Dealers Only If you have an MQ Account to obtain a Order parts on line using Multiquip s SmartEquip website Username and Password E mail us at View Parts Diagrams parts multiquip com E Order Parts To obtain an MQ Account contact your PE SNE Goto www multiquip com and click on Use the internetand qualify for a 5 Discount Parts to log in and save on Standard orders for all orders which include 5 4 r I Order via Fax Dealers Only Fax your order in and qualify for a 226 Discount All customers welcome to order parts Fax on Standard orders for all orders which include Domestic US Customers dial Note Discounts Are Subject To Change Order via Phone Domestic US Dealers Call p ee asi GE SSE 7 PE 7 Non Dealer Customers International Cust Contact your local Multiquip Dealer for MEGA parts or call 800 427 1244 for help in their local Multiquip Representatives for ple J _ 4 When ordering parts please supply Dealer Account Number CJ Specify Preferred Method of Shipment CJ Dealer Name and Address UPS Fed
24. as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months priortothe return date c Anylineitem with anextendeddealer netprice ofless than 5 00 d Specialorder items e Electrical components f Paint chemicals and lubricants 9 Decalsandpaper products h Items purchasedin kits 7 The sender will be notified of any material receivedthatis not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returnedtothe sender at his expense 9 Crediton returned parts willbe issued at dealer net price at time of the original purchase lessa 15 restockingcharge 10 Incases where anitem is accepted for which the original purchase document cannot be determined the price will be based onthe list price that was effective twelve months prior to the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on a spe cific 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 notbe made for stock on hand at the time of any price change Multiquip reserves the
25. bends 10 to 15 mm Figure 38 when depressed with the thumb as shown below 7 10 M DEFLECTION NEVER place hands near the belts or fan while the generator set is running 37 DCA 600SSV SETUP 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 Battery Cable Installation ALWAYS be sure the battery cables Figure 39 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 ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST NEGATIVE POSITIVE
26. in Figure 29 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 e 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 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 Tighten both cocks and replace the overflow tank Replace with coolant as recommended by the engine manufaturer Close radiator cap tightly 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 AX WARNING BURN HAZARDS Allow engine to cool when flushing out radiator Flushing the radiator while hot could cause serious burns from water or tq steam Radiator Cleaning The radiator Figure 70 should be sprayed cleaned with a high pressure washer when excessive amouts of dirt and debris have accumulated on the cooling fins or tube When using a high pressure washer stand at least 5 feet 1 5 meters away from the radiator to prevent damage to
27. 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 To ensure adequate starting capability always have power applied to the generator s internal battery charger OUTPUT TERMINAL BATTERY CHARGER 120 VAC INPUT RECEPTACLE CONNECT TO EXTERNAL 120 VAC POWER SOURCE PANEL JACKET WATER HEATER 120 VAC INPUT RECEPTACLE REFERENCE TABLE 6 FOR PROPER SIZE EXTENSION CORD Figure 71 Battery Charger amp Jacket Water Heater Power Connections DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 47 DCA 600SSV TRAILER BRAKES MAINTENANCE Electric Brakes Electrically actuated brakes Figure 72 are similar to hydraulic brakes The basic difference is that hydraulic brakes are actuated by an electromagnet Listed below are some of the advantages that electric brakes have over hydraulic brakes Brake system can be manually adjusted to provide the corrected braking capability for varying road and load conditions Brake system can be modulated to
28. of old air filter it may not be cleaned or reused DCA 600SSV MAINTENANCE Service Daily If the engine is operating in very dusty or 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 more 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 Cleaning Inside the Fuel Tank Drain the fuel inside the fuel tank completely Using a spray washer Figure 69 wash out any deposits or debris that have accumulated inside the fuel tank Figure 69 Fuel Tank Cleaning Fuel Tank Inspection In addition to cleaning the fuel tank the following components should be inspected for wear Rubber Suspension look for signs of wear or deformity due to contact with oil Replace the rubber suspension if necessary Fuel Hoses inspect nylon and rubber hoses for signs of wear deteration and hardning Fuel Tank Lining inspect the fuel
29. 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 NEVER use accessories or attachments which are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties Whenever necessary replace nameplate operation and safety decals when they become difficult read ALWAYS check the machine for loosened threads or bolts before starting 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 touch the hot exhaust manifold or cylinder Allow these parts to cool before servicing engine or generator HighTemperatures Allow the engine to cool before performing service and maintenance functions Contact with hot components can cause serious burns The engine of this generator requires an adequate free flow of cooling air NEVER operate the generator in any enclosed or narrow area w
30. refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank ONLY use 2 diesel fuel when refueling DO NOT fill on unlevel ground Fuel from the secondary inner tank will eventually drain into the primary trailer tank Siea Ground Figure 32 Only Fill on Level Ground 2 Trailer Fuel Tank First The trailer fuel tank is the primary fuel tank and holds a larger capacity of fuel The fuel in the trailer will be filtered and sent to the engine ALWAYS fill trailer fuel tank Figure 33 first DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 35 DCA 600SSV SETUP 3 NEVER overfill trailer fuel tank It is important to read the trailer fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck See Figure 34 FUEL GAUGE LOCATED ON CONTROL PANEL LAMA AA ZAZ ZZ Z Z Figure 34 Full Trailer Tank A CAUTION REFUELING THE GENERATOR DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expands when heated Figure 36 4 the trailer tank is full the secondary inner tank can be filled See Figure 35 Notice how the trailer filler tube level rises when the internal tank is filled DIESEL FUEL INTERNAL SECONDARY INTERNAL FUEL TANK SIGHT GAUGE TANK ALWAYS FILL INTERNAL TANK LAST ri 1717 at MA AM IA AL th ttl o
31. rightto quote and sell directto Government agencies andto Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 35 00surcharge willbe added tothe invoice for special handling including bus shipments insured parcel post orin cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damages in excess ofthe purchase price of the itemwith respectto which damages are claimed andinno 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 orimplied are made in connection withthe saleofpartsortrade acces sories norasto any engine not manufactured byMultiquip Such warranties made in connec tion with the sale of new complete units are made exclusively by statement of warranty packaged with such units and Multiquip nei ther assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apartfrom such written statement of warranty there are no warranties express implied or statutory which extend beyond the description ofthe products on the face hereof PAGE 106 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 NOTE PAGE
32. the fins and tube Figure 70 Air Cleaner Indicator 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 PAGE 46 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV MAINTENANCE Jacket Water Heater and Internal Battery Charger 120VAC 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 71 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
33. to exceed 15 MPH or less depending on type of terrain Place chock blocks underneath wheel to prevent rolling while parked Use the trailers 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 trailers bumper to prevent tipping while parked Avoid sharp turns to prevent rolling DO NOT transport generator with fuel in tank orn KIT nearest phone or keep a phone on the job site in case of emergencies ALWAYS have easy access to the phone numbers of the nearest Ambulance Doctor and Fire Department This information will be invaluable in the case of an emergency Emergencies ALWAYS know the location of the nearest fire extinguisher ALWAYS know the location of the nearest and first aid kit ALWAYS know the location of the 000 mmm mca DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 13 DCA 600SSV GENERATO
34. to the the OUT side of the pump and turn on the battery switch Remove the plug from the pump and feed priming oil Then turn on the pump main body switch and drain oil from the oil pan 2 Precautions Operate the pump only after feeding a sufficient amount of priming oil do not idle the pump Use the priming oil of the same kind with that to be pumped up The rating of the pump is 25 minutes Do not operate the pump continuously over that value Always keep the main body switch OFF unless replacing oil P N 0840611903 Figure 2 Generator Decals DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 15 DCA 600SSV GENERATOR DECALS Em PANEL LIGHT P N C0551000404 SWITCH 5 3033 P N 0840624604 P N 08006 89404 P N 08006 89504 e DECREASE INCREASE BATTERY SWITCH DON T TURN THE SWITCH OFF DURING OPERATION 605100050 0840624804 P N C0551000704 VOLTAGE REGULATOR 3034 PREHEAT LAMP CIRCUIT 5 3036 P N 0840625004 3031 P N 08406 24504 e L WARNING ELECTRIC SHOCK HAZARD Do not touch internal wiring or connections wh e this machine is operating Turn power off before servicing 893110060 P N B9531100604 WARNING HOT COOLANT can cause severe burns ELECTRIC SHOCK HAZARD A ways comp ete the grounding path from the ground termina on this genset to an external grounding source See nstruct on manua
35. viscosity of fuel or engine oil at low temperature Fuel with low cetane number Clean fuel pipe Clean or change fuel filter Use the specified fuel or engine oil Use the specified fuel Fuel leak due to loose injection pipe retaining nut Engine does not start Incorrect injection timing Fuel cam shaft worn Tighten nut Replace Injection nozzle clogged Clean injection nozzle Injection pump malfunctioning Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace Repair or replace Compression leak from cylinder Improper valve timing Piston ring and liner worn Excessive valve clearance Battery discharged Starter malfunctioning Starter does not run Key switch malfunctioning Wiring disconnected Replace head gasket tighten cylinder head bolt glow plug and nozzle holder PAGE 56 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV TROUBLESHOOTING ENGINE TABLE 18 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Fuel filter clogged or dirty Clean or change Air cleaner clogged Clean or change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace Engine revolution is not smooth Incorrect nozzle opening pressure Injection nozzle stuck or clogged Repair or replace Fuel over flow pipe
36. 0 2 Connecttheload wires to the UVWO terminals as shown in Figure 24 Gi b GROUND CONNECTION MUST BE USED 0 AT ALL TIMES SINGLE PHASE 120 VAC LOAD CONNECTIONS Figure 24 UVWO Terminal Lugs 10 120V Connections PAGE 32 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV OUTPUT TERMINAL PANEL CONNECTIONS 30 480V UVWO Terminal Output Voltages 10 480V UVWO Terminal Output Voltages 1 Jumperthe voltage change over board for 480V operation 1 Make sure the voltage change over board is jumpered as shown in Figure 25 This configuration uses 6 jumper for 480V operation as shown in Figure 25 plates in 3 different positions Remember there are 2 5 Connect the load wires to the UVWO terminals as shown jumper plates at every position Every jumper plate must in Figure 27 m be used USE 2 JUMPER PLATES AT EACH POSITION N Figure 265 Voltage Change Over Board 480V Configuration 480 VAC LOAD CONNECTIONS 2 Connectthe load wires to the UVWO terminals as shown Figure 27 UVWO Terminal Lugs in Figure 26 REEN _ 10 480V Connections 10 277V UVWO Terminal Output Voltages MUST BE USED 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 25 2 Connectthe load wires to the UVWO terminals as shown in Figure 28 GREEN GROUND CONNECTION M 0 AT ALL TIMES THREE PHASE 480 VAC LOAD CONNECTIONS Figure 26 UVWO
37. 01504 DECAL RESET 3 1 6360610304 DECAL WATER 3 2 6360620204 DECAL OIL DRAIN PLUG 3 3 89504000404 DECAL WARNING MOVING PARTS 3 4 B9504100104 DECAL WARNING HOT COOLANT 3 5 6551002704 DECAL COOLING WATER DRAIN PLUG 3 6 04551003103 DECAL AIR BLEEDING PROCEDURE 4 1 C0551000504 DECAL BATTERY SWITCH 4 2 4551002804 DECAL ALARM LAMP 4 3 4551002904 DECAL EMERGENCY ENGINE SPEED 4 4 C4551003004 DECAL PREHEAT 45 4551003204 DECAL HOUR METER 5 1 C0551000404 DECAL 3 PHASE OUTPUT TERMINAL 5 2 0840614104 DECAL GROUND 5 3 08406199044 DECAL DANGER HIGH VOLTAGE 5 4 9039209064 DECAL START CONTACT 55 0840655704 DECAL TERMINAL COVER STOPPER 5 6 B9511100304 DECAL WARNING 5 7 9511100404 DECAL WARNING ELECTRIC SHOCK HAZARD 5 8 B9531100504 DECAL WARNING ELECTRICK SHOCK HAZARD 5 9 4551001703 DECAL RECEPTACLE 8 CIRCUIT BREAKER 6 1 0800689404 DECAL 6 2 0800689504 DECAL 6 3 9505300004 DECAL CAUTION DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 103 QTY 1 2 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DCA 600SSV NAMEPLATE AND DECALS CONT NAME PLATE AND DECALS i 2 4 2 6 2 5 2 16 2 10 T z 4 deem ges N 4 5 4 2 4 4 4 3 PAGE 104 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 0
38. 02404 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 93 DCA 600SSV ENCLOSURE 1 ASSY CONT PART NAME HEX HEAD BOLT HEX NUT SPRING WASHER PLAIN WASHER COVER HEX HEAD BOLT HEX NUT COVER HEX HEAD BOLT ROOF PANEL ROOF PANEL ROOF PANEL HEX NUT COVER HEX HEAD BOLT HEX HEAD BOLT GUTTER TY REMARKS CD NNN HY nO no CO CO CO DCA 600SSV ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY PAGE 94 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 ENCLOSURE 2 ASSY NO 1 C4444001303 2 3875151004 3 0207106000 4 C4444000103 5 C4444000203 6 7 8 C4444000303 0017110025 0017108020 9 0019210025 10 7975155003 10A 3875944104 11 3875151104 12 0207006000 13 C4444301204 13 8495946104 14 0017108020 15 0019208020 16 C4444300703 17 3875165803 18 0019208020 19 7975143003 20 C4444201503 21 3875147204 22 3875147304 23 0207306000 24 B9114000102 25 0021806015 26 7975146004 27 7975146104 28 0845050704 29 0207106000 30 0805011304 31 0805011204 32 0207106000 33 0845047104 33A 0845045004 34 0845047204 34A 0845045004 35 0019208020 36 0845031504 37 0601850097 38 0025408025 39 0600800320 40 0207106000 41 4464202303 4494501604 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 95 PART NAME REAR FRA
39. 07 13 09 PAGE 41 DCA 600SSV GENERATOR START UP PROCEDURE AUTO MODE 23 Observe the generator s ammeter Figure 61 and verify it reads the anticipated amount of current with respect reading if a load is in use Figure 61 Ammeter Load 24 The generator will run until manually stopped or an abnormal condition occurs AX DANGER ELECTRICAL SYSTEM HAZARDS Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious damage to the d building s electrical system may occur without this transfer switch CAUTION BACKUP GENERATOR USE 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 AX WARNING AUTO MODE MAINTENANCE 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 AX CAUTION ENGINE SPEED SWITCH 6 The Engine Speed Switch must be set to the High 7 position when running in the Auto Start mode Failing to set the switch in the proper position can result in damage to your generator when it turns on When starting generator in AUTO mode use the Manual Start up procedure except where noted see below to the load
40. 13 09 PAGE 3 TABLE OF CONTENTS MQ Power DCA 600SSV 60 Hz AC Generator California Proposition 65 Warning 2 Reporting Safet Defects 2222222 3 Table of Contents MP 4 Parts Ordering Procedures 5 Specifications REN 6 Dimensions Top Side Front 7 Safety Alert Messages SymbolS 8 9 Rules tor Sale Operation 10 13 Generator Decals 14 17 LEE 18 19 General Information 20 Major Components egene 21 Generator Control 22 23 Engine Operating Panel 24 25 Output Terminal Panel Familiarization 26 28 LoadApplication UU n EA enter 29 Generator Outputs iai Sestri 30 Generator Outputs Gauge Reading 31 Output Terminal Panel Connections 32 33 Pie SGL t C qana 34 38 Generator Start up Procedure Manual MPEC 39 41 Generator Start up Procedure Auto MPEC 42 Generator Shutdown Procedure 43 Maintenance Engine sss 44 47 Maintenance Trailer 48 50 Trailer Wiring Diagram 51 52
41. 34B 0040020000 34C 0041220000 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 91 PART NAME BASE FLOOR PANEL HEX HEAD BOLT FLOOR PANEL FLOOR PANEL FLOOR PANEL HEX HEAD BOLT COVER HEX HEAD BOLT GUIDE PANEL AIR ACOUSTIC SHEET RUBBER SEAL HEX HEAD BOLT GUIDE PANEL AIR GUIDE PANEL AIR HEX HEAD BOLT FRONT FRAME ACOUSTIC SHEET FRONT FRAME ACOUSTIC SHEET FRONT FRAME ACOUSTIC SHEET FRONT FRAME ACOUSTIC SHEET HEX HEAD BOLT GUIDE PANEL AIR ACOUSTIC SHEET GUIDE PANEL AIR ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT COVER FROM FRAME COVER FROM FRAME ACOUSTIC SHEET HEX HEAD BOLT FILLER BRACKET HEX HEAD BOLT COVER HEX HEAD BOLT COVER FRONT FRAME HEX HEAD BOLT CENTER FRAME HEX HEAD BOLT HEX NUT SPRING WASHER PLAIN WASHER DCA 600SSV ENCLOSURE 1 ASSY Q TY REMARKS CD ASSY CONT ENCLOSURE 1 gt o co DCA ENCLOSURE 1 ASSY a gt 5 R RE gt LLI lt 2 lt CD lt a lt lt a gt CD 72 2 lt a LLI lt ENCLOSURE 1 ASSY PART NO 0010120065 0030020000 0040020000 0041220000 C4434200103 0017108020 0207008000 C2367700404 0019208020 C4464102903 C4464103003 C4464103103 0207108000 8452023004 0019208020 0019208020 C44645
42. 4 DRAIN HOSE 45 C4322600104 DRAIN HOSE 46 0605515073 HOSE BAND 47 C4324100303 BREATHER TANK 48 0019208025 HEX HEAD BOLT 49 0603325011 VALVE 50 0602022293 HOSE JOINT 51 0268800680 BREATHER HOSE 52 0268801560 BREATHER HOSE 53 0605515138 HOSE BAND 54 0191302200 OVERFLOW HOSE 55 0605515109 HOSE BAND 56 C4358300704 CLAMPER ROD 57 C4358300604 CLAMPER ROD 58 0012310030 HEAD BOLT 59 0207010000 HEX HEAD BOLT DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 77 QTY REMARKS Po po PE A gt JO O DCA 600SSV ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY PAGE 78 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY NO 1 C4484002102 2 0017112030 3 0017110030 4 C4352102203 5 0017108020 6 0017108020 7 8085182004 8 8085183004 9 0017106020 10 0602101012 11 0805008804 12 0805008704 13 0021008070 13A 0040008000 13B 0041208000 14 0601830448 15 0602103090 15A 0601810244 16 0602120023 16A 0602129120 17 0602122026 17A 0602122026 18 0602123023 18A 0602129121 19 0602125055 20 0601831570 21 0602103090 21A 0601810244 22 0601830710 23 0601831954 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 79 PART NAME SUPPORT LEG HEX HEAD BOLT HEX HEAD BOLT OPERATING P
43. 4304201004 ENGINE FOOT 2 3 4 5 C4304200904 ENGINE FOOT 6 7 8 0013616040 HEX HEAD BOLT 16 0040016000 SPRING WASHER 16 0041216000 PLAIN WASHER 16 0605000012 RUBBER SUSPENSION 4 0030020000 HEX NUT 8 0040020000 SPRING WASHER 8 C4311100604 BRACKET RADIATOR 2 0017108025 HEX HEAD BOLT 4 0017110025 HEX HEAD BOLT 4 0010112035 HEX HEAD BOLT 4 0030012000 HEX NUT 4 0040012000 SPRING WASHER 4 0041212000 PLAIN WASHER 8 6452025504 DRAIN JOINT 1 0802024004 PACKING 1 0130008000 ELBOW JOINT 1 0602022294 HOSE JOINT 2 C0321200004 DRAIN JOINT 1 C0321300004 CAP 1 0019208025 HEX HEAD BOLT 2 0603325017 VALVE 1 0265801000 DRAIN HOSE 1 0605515074 HOSE BAND 2 0602012342 PACKING 1 0603306592 ADAPTER 1 0603306869 ADAPTER 1 0602012071 VALVE 1 0602040666 INDICATOR AIR CLEANER 1 0602046007 NIPPLE 1 0845035004 PACKING 2 0845500304 NIPPLE 2 B1368701103 DRAIN JOINT 1 0802011104 PLUG 1 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 75 DCA 600SSV ENGINE AND RADIATOR ASSY CONT ENGINE AND RADIATOR ASSY e4 23 2622 28 VIEW Y PAGE 76 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV ENGINE AND RADIATOR ASSY CONT ENGINE AND RADIATOR ASSY NO PART NAME 39 0150000018 O RING 40 0019206025 HEX HEAD BOLT 41 0130404000 T JOINT 42 0130204000 STREET ELBOW 43 0602022291 HOSE JOINT 44 C432260000
44. 55 Contact cnavarro multiquip com br srentes multiquip com br COPYRIGHT 2007 MULTIQUIP INC Multiquip Inc the MQ logo and the MQ Power 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 are based on the MQ Power Model DCA150SSV 60 Hz Diesel Powered Generator 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 Manufactured for Multiquip Inc b y DENYO CO LTD JAPAN Your Local Dealer is MQPOWER A Division of Multiquip Inc M POST OFFICE BOX 6254 CARSON CA 90749 310 537 3700 800 421 1244 FAX 310 632 2656 POWE E mail mqpower multiquip com Internet www mqpower com
45. 9 DCA 600SSV NAMEPLATE AND DECALS CONT NAME PLATE AND DECALS NO PART NO PART NAME QTY REMARKS 7 1 89504200004 DECAL WARNING ENGINE EXHAUST 1 7 2 89511100204 DECAL CAUTION HOT SURFACES 1 8 1 1320620904 DECAL DIESEL FUEL 1 8 2 6360620004 DECAL FUEL DRAIN PLUG 1 8 3 0840607104 DECAL FUEL GAUGE 1 84 89504500004 DECAL WARNING DIESEL FUEL 1 9 1 0800615102 DECAL CAUTION AGAINST OIL AND 1 9 2 1320610603 DECAL WATER OIL 1 9 3 1320621504 DECAL SUPPORT HOOK 2 9 4 0840625902 DECAL MQ 1 9 5 B9504000304 DECAL CAUTION HOT PARTS 1 9 6 B9521100404 DECAL SAFETY INSTRUCTIONS 1 9 7 B9531100604 DECAL WARNING ELECTRIC SHOCK HAZARD 1 9 8 0600500090 EMBLEM 2 4 1 1 1 2 2 2 1 1 2 9 8A 0021106016 MACHINE SCREW 9 9 C4561101603 STRIPE 9 10 4561102503 STRIPE 9 11 C4561102303 STRIPE 9 12 C4561102204 STRIPE 9 13 04561102604 STRIPE 9 14 4561102104 STRIPE 9 15 04561102403 STRIPE 9 16 04561102003 STRIPE 9 17 04561102704 STRIPE DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 105 Effective October 1 2002 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 10 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges addedtothe invoice All shipments are F O B point of origin Multiquip s responsibility ceases when asigned manifest has been obtained from the carrier andany claimforshortage ordamage mustbe set
46. ANEL HEX HEAD BOLT HEX HEAD BOLT RUBBER COVER SET FRAME RUBBER COVER HEX HEAD BOLT BATTERY SWITCH SET PLATE BATTERY SWITCH STAY BATTERY SWITCH MACHINE SCREW SPRING WASHER PLAIN WASHER PREHEAT BUTTON PREHEAT LAMP BULB TACHOMETER MOUNT KIT OIL PRESSURE GAUGE MOUNT KIT WATER TEMPERATURE GAUGE MOUNT KIT FUEL GAUGE SWITCH HOUR METER ALARM LAMP BULB CHANGE OVER SWITCH SPEED EMERGENCY STOP BUTTON QTY REMARKS 1 4 2 1 4 6 2 2 2 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 5 5 1 1 DCA 600SSV OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY PAGE 80 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV OUTPUT TERMINAL ASSY OUTPUT TERMINAL ASSY NO PART NAME QTY REMARKS 1 C4231700603 SET BOARD OUTPUT TERMINAL 1 2 7521860504 OUTPUT TERMINAL 4 3 7521850504 BRACKET OUTPUT TERMINAL 4 4 0010112040 HEX HEAD BOLT 8 4A 0030012000 HEX NUT 8 4B 0040012000 SPRING WASHER 8 4C 0041212000 PLAIN WASHER 16 5 0010112045 HEX HEAD BOLT 8 5A 0030012000 HEX NUT 8 5B 0040012000 SPRING WASHER 8 5C 0041212000 PLAIN WASHER 16 6 0010112040 HEX HEAD BOLT 24 6A 0030012000 HEX NUT 24 6B 0040012000 SPRING WASHER 24 6C 0041212000 PLAIN WASHER 48 7 0801830404 TERMINAL 1 8 0801830904 HEX HEAD BOLT 1 9 0039320000 HEX NUT 2 10 0040020000 SPRING WASHER 3 11 0041420000 PLAINWASHER 4 12 0019112050 HEX HEAD BOLT 6
47. E 1 24 0027103020 MACHINE SCREW 2 25 0601823240 RECTIFIER 1 26 0027105020 MACHINE SCREW 1 27 0601842461 RESISTOR 1 28 0027103020 MACHINE SCREW 1 29 0601828533 RELAY 1 30 0027104016 MACHINE SCREW 2 31 0602202691 CONTROLLER 1 32 0017106016 HEX HEAD BOLT 3 33 0601815402 TERMINAL BOARD 1 34 0027104020 MACHINE SCREW 2 35 0601815941 TERMINAL BOARD 1 36 0027104020 MACHINE SCREW 2 37 0601807516 CIRCUIT BREAKER 1600 AMPS 1 38 0015308045 SOCKET HEAD CAP SCREW 8 38A 0042508000 SPRING WASHER 8 38B 0041208000 PLAIN WASHER 8 39 0010114055 HEX HEAD BOLT 12 39A 0030014000 HEX NUT 12 39B 0040014000 SPRING WASHER 12 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 69 DCA 600SSV CONTROL BOX ASSY CONT CONTROL BOX ASSY e S gt i PAGE 70 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV CONTROL BOX ASSY CONT CONTROL BOX ASSY NO PART NAME QTY REMARKS 39 0041214000 PLAIN WASHER 24 40 7431861113 CHANGE OVER BOARD VOLTAGE 1 41 7431852104 CHANGE TERMINAL 10 42 0017108035 HEX HEAD BOLT 20 43 7971852504 TERMINAL PLATE 7 44 7431853104 CHANGE PLATE 6 45 0801832504 HEX HEAD BOLT 17 46 0801830904 HEX HEAD BOLT 3 47 0040020000 SPRING WASHER 20 48 0041420000 PLAIN WASHER 20 49 0010110040 HEX HEAD BOLT 49A 0030010000 HEX NUT 49B 0040010000 SPRING
48. EPLATE AND DECALS NAME PLATE AND DECALS J 3 4 L3 ENAR 9 10 9 8 le 9 15 1 2 NEL T 9 17 Loy 9 3 8 2 3 5 L 2 PAGE 102 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV NAMEPLATE AND DECALS NAME PLATE AND DECALS NO PART NAME 1 1 C3551002303 DECAL HANDLING PROCEDURES 12 C9522100003 DECAL CAUTION 2 1 0800520100 PLATE ON OFF 2 2 0800520904 PLATE AMMETER CHANGE OVER SWITCH 2 3 0800520814 PLATE VOLTMETER CHANGE OVER SWITCH 2 4 0800564004 DECAL OFF 2 5 0800565004 DECAL ON 2 6 0840624504 DECAL CIRCUIT BREAKER 2 7 0840624604 DECAL PANEL LIGHT SWITCH 2 8 0840624704 DECAL PILOT LAMP 2 0 0840624804 DECAL VOLTAGE REGULATOR 2 10 9531100604 DECAL WARNING ELECTRIC SHOCK HAZARD 2 11 C3551001004 DECAL DIAGNOSTIC LAMP 2 12 C3551003204 DECAL CAUTION ECU 2 13 4561101903 DECAL WHISPERWATT 600 2 14 C9502400004 DECAL HIGH IDLE SPEED 2 15 9521007004 DECAL ISO DROOP CHANGE OVER SWITCH 2 16 9521203003 DECAL SETTING FOR OUTPUT VOLTAGE 2 17 201100
49. IC LAMP RESET SWITCH Figure 79 Diagnostic Panel Method of Operation 1 Normally the diagnostic lamp will be dimly lit when the MPEC Control Switch is placed in the MANUAL position 2 f engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position 3 The diagnostic lamp will indicate an error code via a flashing pattern on the lamp This pattern will become visible once the the reset button on the control box has been pushed and released The error code consists of a series of flashes by the lamp The error codes are defined as follows Example Error Code 1 Figure 80 displays the error code for low radiator coolant NOS NOS NO BLINK FOR pa 2 2 SECONDS 2 ANN ANN LAMP FLASHES TWICE LAMP FLASHES TWICE Figure 80 Error Code Low Radiator Coolant Example Error Code 2 Figure 81 displays the error code for high temp intake NO BLINK FOR 2 SECONDS gt 74 LAMP FLASHES TWICE N 4 Io ad LAMP FLASHES SIX TIMES Figure 81 Error Code High Temperature Intake The error code will flash each time the reset button is pressed and released until the problems have been corrected 4 Ina situation where several engine malfunctions occur simultaneously the code for each malfunction will flash one after another in sucession 5 After all engine related malfunctions have been diagnosed and corrected and
50. IN WASHER HEX HEAD BOLT PACKING BRACKET COVER COVER STATOR HEX HEAD BOLT HEX HEAD BOLT COVER EXCITOR HEX HEAD BOLT HEX HEAD BOLT SPRING WASHER COVER FAN HEX HEAD BOLT RUBBER SUSPENSION HEX NUT SPRING WASHER SPACER BEARING BEARING QTY REMARKS A OO WP O WP DCA 600SSV CONTROL BOX ASSY CONTROL BOX ASSY PAGE 68 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV CONTROL BOX ASSY CONTROL BOX ASSY NO PART NAME QTY 1 C4214001602 CONTROL BOX 1 2 0601806153 CURRENT TRANSFORMER AMMETER 3 3 0017108020 HEX HEAD BOLT 6 4 C4261506003 SET PANEL ELECTRIC PARTS 1 5 0017108030 HEAD BOLT 8 6 0601820658 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105015 MACHINE SCREW 4 8 0601820892 OVER CURRENT RELAY 1 9 0027104015 MACHINE SCREW 2 10 C4261601904 SWITCH BRACKET 1 11 0601810575 DIAGNOSTIC LAMP 1 12 0601831205 RESET SWITCH 1 13 3267600004 RESISTOR SWITCH 1 14 0027105020 MACHINE SCREW 1 15 003006000 1 16 0601830710 CHANGE OVER SWITCH 1 17 0017106016 HEX HEAD BOLT 4 18 0601840227 RHEOSTAT HIGH IDLE SPEED REGULATOR 1 19 3262600004 1 20 0017106016 HEX HEAD BOLT 2 21 0601827655 RELAY 4 21A 0601823109 SOCKET 4 21B 0601824400 HOLDER 4 22 0027104015 MACHINE SCREW 8 23 0601802149 FUSE 1 23 0601802211 HOLDER FUS
51. Is wiring connection loose Check wiring and repair No Voltage Output Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace 15 engine speed correct Turn engine throttle lever to High Low Voltage Output Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary Is wiring connections loose Check wiring and repair High Voltage Output Defective AVR Replace if necessary Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Circuit Breaker Tripped Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 58 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV TROUBLESHOOTING ENGINE CONTROLLER Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 20 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 TABLE 20 ENGINE CONTROLLER TROUBLESHOOTING MPEC Low oil level Fill oil level Low oil pressure light Oil pressure sending unit failure Replace oil pressure sending unit RL Time delay malfuntion in Controller Refer to dealer Wire shorted Inspect repair wire
52. ME LOUVER PANEL HEX NUT REAR FRAME REAR FRAME REAR FRAME HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT COVER REAR FRAME ACOUSTIC SHEET LOUVER PANEL HEX NUT DUCT COVER ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT VISOR VISOR HEX HEAD BOLT DOOR REAR FRAME DOOR REAR FRAME WINDOW PLATE WINDOW PLATE SUPER LOCK NUT DOOR HANDLE MACHINE SCREW DOOR ROD DOOR ROD STAY HEX NUT STOPPER DOOR STOPPER DOOR HEX NUT HINGE WASHER HINGE WASHER HEX HEAD BOLT CAP STOPPER MACHINE SCREW MANUAL PACK HEX NUT ROOF PANEL ACOUSTIC SHEET DCA 600SSV ENCLOSURE 2 ASSY QTY REMARKS 1 1 21 W gt O WP 00 LC 1 OI 600 ENCLOSURE 2 ASSY CONT ENCLOSURE 2 ASSY PAGE 96 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 ENCLOSURE 2 ASSY NO 42 C4464202403 42 4494501604 43 4464202503 43 4494501604 44 4464501804 45 4464502304 45 4494501604 46 0207008000 47 4464502204 47 4494501704 48 4464502104 48 4494501704 49 0017108020 50 0019208020 51 4374200503 51 1 0310000520 52 0017108020 53 3374200104 54 0017108020 55 0019210025 56 4464502504 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 97 DCA 600SS
53. MET 39 C4237102804 COVER 40 C4237400804 BRACKET 41 0017106016 HEX HEAD BOLT DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 83 DCA 600SSV BATTERY ASSY BATTERY ASSY PAGE 84 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV BATTERY ASSY BATTERY ASSY NO PARTNO PART NAME QTY REMARKS 1 0168719052 BATTERY 2 2 C9109100704 BATTERY SHEET 2 3 0805007804 BATTERY BAND 2 4 0805006504 BATTERY BOLT 2 5 0037808000 WING NUT 4 6 0040008000 SPRING WASHER 4 7 0041208000 PLAIN WASHER 4 8 C5347600504 BATTERY CABLE 4 9 C4347601704 BATTERY CABLE 1 10 7432280504 BATTERY CABLE 1 11 C4347601904 BATTERY CABLE 1 12 04347601804 EARTH CABLE 1 13 0347010030 HEX HEAD BOLT 4 14 0208110000 HEX NUT 4 15 0845040114 TERMINAL 2 16 0845041004 TERMINAL CAP 2 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 85 DCA 600SSV MUFFLER ASSY MUFFLER ASSY PAGE 86 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 MUFFLER ASSY NO 1 C4331100802 2 0019210020 3 C4334200904 4 C4334200904 5 0019210030 6 0019208020 7 C4334000903 8 C4334001003 9 0602325009 10 C4334200504 11 0010116050 0040016000 11B 0041216000 12 C4484100004 13 0012310025 14 0012310030 15 C4334103603 16 C3334200704 17 0010112050 17A 0030012000 17B 0040012000 17C 0041212000 18 4331301204
54. OPERATION AND PARTS MANUAL POWER WHISPERWATT SERIES MODEL DCA 600SSV 60 Hz GENERATOR PARTS LIST NO C4874303204 Revision 0 07 13 07 THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Multiquip at 1 800 421 1244 If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Multiquip To contact NHTSA you may either call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator NHTSA 1200 New Jersey Avenue S E Washington DC 20590 You can also obtain information about motor vehicle safety from http www safecar gov DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07
55. OWTOWING REGULATIONS 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 ALWAYS shutdown engine before transporting Tighten both fuel tank caps securely M If generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws Follow the listed Towing amp 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 8 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 The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not
56. R ON SWITCH 80 80mm BROWN CIRCUIT BREAKER OFF SWITCH 22 22mm G GREEN 14 14mm GRAY 8 8mm V VIOLET O 55 5 5mm P PINK NO MARK WIRE SIZE 1 25 mm CIRCUIT BREAKER OFF LAMP Figure 75 Main Circuit Breaker Wiring Diagram PAGE 54 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV ENGINE WIRING DIAGRAM Fs FR 639 49 WH RELAY INSIDE CONNECTION 10 1 S AUTEM ALTERNATOR BATTERY WIRE SIZE TABLE 9191919191019101919191919101916101015 COLOR CODE WIRE COLOR WIRE COLOR BLACK R RED BR BROWN v YELLOW _ Lv VIOLET O ORANGE FOR ENGINE CONTROL UNIT DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 55 DCA 600SSV TROUBLESHOOTING ENGINE Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 18 Engine Troubleshooting as a basic guideline for troubleshooting the engine If the problem cannot be remedied consult our company s business office or service plant TABLE 18 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM No fuel Air in the fuel system Water in the fuel system SOLUTION Replenish fuel Bleed system Remove water from fuel tank Fuel pipe clogged Fuel filter clogged Excessively high
57. R DECALS Machine Safety Decals The DCA 600SSV generator is equipped with a number of safety decals These decals are provided for operator safety and maintenance information The illustrations below and on the preceding pages shows the decals as they appear on the machine Should any of these decals become unreadable replacements can be obtained from your dealer WARNING HOT SURFACES can burn skin Do not get on the roof until the machine is W cooled sufficiently EEE P N B9511100204 B91110020 we A WARNING DO NOT LOSSEN CAP WHEN WATER TEMPERATURE IS HIGH IF LOOSENED BOILING WATER MAY GUSH OUT BECAUSE OF HIGH INTERNAL HIGHT 09668 10000 P N 0966810000 ALARM OIL FILTER 4512 0840655604 STOP BUTTON 5 878 P N 0800686004 P N 0840607104 CAUTIONS AGAINST OIL AND FUEL INFILTRATION Should oil or fuel infiltrate into the internal sound absorbing materials it will cause trouble Strictly observe the following to keep the machine interior constantly clean Sage Han gr FUEL Feed Exercise care not to spill oil against fuel infiltration P N 0800688404 Filter cleaning Air vent Apply a piece of cloth or similar material to safegaurd When detaching the filter for cleaning apply a piece Saige pmi roy FUEL OUTLET Oil Feed Exercise care not to spill oil Filter cleaning 5 1345 of cloth or similar material to prevent fuel fr
58. UT TERMINAL FAMILIARIZATION Output Terminal Familiarization Output Terminal Panel The Output Terminal Panel Figure 8 is provided with Shown below Figure 8 is the Output Terminal Panel lift the following up on the cover to gain access to receptacles and terminal lugs Three 240 139V output receptacles 50 amp Three AUX circuit breakers 240V 950 amps Two 120V GFCI receptacles 20 amp Two 2 GFCI circuit breakers 120V 9 20 amps Eight 16 output terminal lugs Terminal legs O and Ground e e are considered bonded grounds e e Figure 8 Output Terminal Panel CIRCUIT BREAKERS 19 AND 30 FOR CS 6369 TWIST 120 480 VAC LOCK RECEPTACLES OUTPUT TERMINALS GROUND TERMINAL CIRCUIT BREAKERS FOR RECEPTACLES 120 VAC 20 AMP GFCI RECEPTACLES CS 6369 TWIST LOCK POWER OUTPUT AUX POWER RECEPTACLES TERMINAL PANEL 139 240V 50 AMPS PAGE 26 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV OUTPUT TERMINAL PANEL FAMILIARIZATION 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 change over board 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
59. V ENCLOSURE 2 ASSY CONT PART NAME ROOF PANEL ACOUSTIC SHEET ROOF PANEL ACOUSTIC SHEET GUTTER PANEL ACOUSTIC SHEET HEX NUT COVER ROOF PANEL ACOUSTIC SHEET COVER ROOF PANEL ACOUSTIC SHEET HEX HEAD BOLT HEX HEAD BOLT COVER AIR CLEANER RUBBER SEAL HEX HEAD BOLT COVER AIR CLEANER HEX HEAD BOLT HEX HEAD BOLT GUTTER QTY REMARKS DCA 600SSV ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY PAGE 98 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 ENCLOSURE 3 ASSY NO 1 C4454206003 2 0019110070 2A 0042310000 2 B 0042410000 3 C4454102803 3A C4494409504 4 C4454102903 4A C4494409404 5 C4454103003 5A C4494409304 6 C4454103103 6A C4494409204 7 C4454004103 7A 4494408604 8 C4454004203 8A C4494408704 9 C4454004303 9A C4494408804 10 C4454004403 10A 4494409104 11 3875151204 12 7975151004 13 0207106000 14 C4454301904 14A 4494408904 15 C4454302004 15A 4494409604 16 C4453402104 16A 04494409004 17 0207106000 18 B9114000002 19 0825007362 20 0021806015 21 0845046904 21A 0845045004 22 0845047004 22A 0845045004 23 0019208020 24 0601850097 25 0025408025 26 0019208070 27 0845031504 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 99 PART NAME SPLASHER PANEL HEX HEAD BOLT SPRING WASHER PLAIN WASHER SIDE PANEL ACOUSTIC SHEET SIDE PANEL ACOUSTIC SHEET SIDE PANEL ACOUSTIC SHEET
60. WASHER 49C 0041210000 PLAIN WASHER 50 C4224004203 CONTROL PANEL 51 C4225000213 CONTROL PANEL 52 0605011211 PIN 53 0601800480 FREQUENCY METER 220V 54 0601800736 AC AMMETER 55 0601801040 CHANGE OVER SWITCH AMMETER 56 0601800252 AC VOLTMETER 600V 57 0601801041 CHANGE OVER SWITCH VOLMETER 58 0601810072 PILOT LAMP 58A 0601810261 BULB 59 0601840073 RHEOSTAT VOLTAGE REGULATOR 60 0601840121 KNOB 61 0602202640 ENGINE CONTROLLER 62 0027104040 MACHINE SCREW 62A 0207004000 HEX NUT 63 0601830765 SWITCH 64 0601810161 PANEL LIGHT 64A 0601810214 BULB 65 0207004000 HEX NUT 66 0601830710 SWITCH PANEL LIGHT 67 0601810476 OFF LAMP CIRCUIT BREAKER 67 0601810235 BULB 68 0601810467 ON LAMP CIRCUIT BREAKER 68A 0601810235 BULB 69 0601830498 CIRCUIT BREAKER RESET SWITCH po po fp 2 A HSH HSH HS HS HS SH HSH PP PE L m 70 0601831224 CIRCUIT BREAKER SWITCH 71 C9221100004 HEX HEAD BOLT 71A 0040008000 SPRING WASHER 718 0041208000 PLAIN WASHER 71C 0080200007 SNAP RING 72 3871824004 STOPPER CONTROL PANEL 73 0041206000 PLAIN WASHER DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 71 DCA 600SSV CONTROL BOX ASSY CONT CONTROL BOX ASSY 5 26 25 PAGE 72 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 CONTROL BOX ASSY NO
61. ard has been provided for ease of voltage selection Rated Voltage JUMPER 6 PLACES Single Phase 120113333 amps 4 wire Volt Singe P nape 240 666 7 amps 4 wire Volt Three Phase 240 Volt 1443 4 amps Three Phase 480 Volt 721 7 amps Figure 14 Voltage Change Over Board 240V Configuration AX DANGER CHANGING JUMPER PLATES NEVER attempt to place jumper plates on the voltage change over board while the generator is in operation There exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even death Table 7 Generator Available Voltages Three Phase 208V 220V 240V 416V 440V 480V Single Phase 120V 127V 139V 240V 254V 277V PAGE 30 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR OUTPUTS GAUGE READING How to Read the AC Ammeter and AC Voltage Gauges The AC ammeter and AC voltmeter gauges are controlled by the Ac ammeter and AC voltmeter change over switches Both of these switches are located on the generator control panel and DO NOT effect the generator output They are provided to help observe how much power is being supplied produced at the UVWO terminals lugs Before taking a reading from either gauge configure the volt age change over board which produces the desired outputvoltage When the voltage change over board is jumpered for 30 240V operation See Figure 15 JUMPER 6 PLACES
62. cates the engine pressure has fallen below 15 psi The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered a major fault and will shut down the generator High Coolant Temperature Indicates the engine temperature has exceeded 215 F The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault and will shut down the generator Overcrank Shutdown Indicates the unit has attempted to be started a pre programmed number of times and has failed to start The number of cycles and duration are programmable Typical programmable start settings is 3 cycles with a 10 second duration This is considered a major fault and will shut down the generator Overspeed Shutdown Indicates that the engine is running at an unsafe speed This is considered a major fault Engine Running Indicates that engine is running at a safe operating speed DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 23 DCA 600SSV ENGINE OPERATING PANEL BATTERY SWITCH LAMP EMERGENCY STOP ENGINE SPEED d PRE HEAT BUTTON Figure 7 Engine Operating Panels PAGE 24 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA 600SSV Eng
63. 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 Volvo 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 CH 4 API Service Classification CG 4 API Service Classification CF 4 ACEA Specification E3 ACEA Specification E2 Table 9 Recommended Motor Oil Temperature Range Type Oil F 14 F 50 10 C 10 C 32 F and above 0 C and above SAE 10W SAE30 or SAE 10W 30 Fuel spillage on a hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel completely to prevent fire hazards NEVER smoke around or near the generator EBSD REFILLING THE FUEL SYSTEM AX CAUTION REFUELING THE GENERATOR ONLY properly trained personel who have read and understand this section should refill the fuel tank system The DCA600SSV series generators may if equipped with a trailer or skid have a double fuel tank system Figure 30 which consists of an internal generator fuel tank and a trailer mounted fuel tank It is also possible the generator can be equipped with a skid mounted fuel tank Figure 32 The skid type fuel system does not use the internal generator fuel tank Use the instructions in this section that
64. clogged Clean Governor malfunctioning Excessive engine oil Reduce to the specified level Piston ring and liner worn or Either white or blue exhaust gas Stuck is observed Repair or replace Incorrect injection timing Adjust Deficient compression Adjust top clearance Overload Lessen the load Low grade fuel used Use the specified fuel Either black or dark gray i 2 exhaust gas is observed Fuel filter clogged Clean or change Air cleaner clogged Clean or change Deficient nozzle injection Repair or replace the nozzle Incorrect injection timing Adjust Engine s moving parts seem to be seizing Repair or replace Deficient output Uneven fuel injection Repair or replace the injection pump Deficient nozzle injection Repair or replace the nozzle Replace head gasket tighten cylinder head bolt glow plug and i 2 Compression leak nozzle holder DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 57 DCA 600SSV TROUBLESHOOTING GENERATOR Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use Table 19 shown below for diagnosis of the Generator If the problem cannot be remedied consult our company s business office or service plant TABLE 19 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION AC Voltmeter defective Check output voltage using a voltmeter
65. ctrical shock NEVER grab or touch a live power 6 cord with wet hands NEVER touch output terminals ower on during operation This is extremely dangerous ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required Backfeed to a utility system can cause electrocution and or property damage DO NOT connect to any building s electrical system except through an approved device or after building main switch is opened ALWAYS have a licensed electrician perform the installation DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 11 DCA 600SSV RULES FOR SAFE OPERATION Maintenance Safety 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 NEVER lubricate components or attempt service on a running machine 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 ALWAYS allow the machine a proper amount of time to cool before servicing Keep the machinery in proper running condition Fix damage to the machine immediately and always replace broken parts ALWAYS service air cleaner fre
66. d Spare Parts List may super cede replace the P N shown in the text pages of this book DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 63 GENERATOR ASSY 600SSV lt a gt 5 R RE gt LLI lt 2 lt CD lt a lt lt a gt CD 72 5 lt 47 a a GENERATOR ASSY GENERATOR ASSY NO 1 4100100202 1 1 1 2 0601842366 1 3 8171020004 14 8171020504 1 5 8461070002 1 6 8461614003 1 7 0010312025 1 8 0042512000 1 9 4163100004 1 10 8461015003 1 11 0012120055 1 12 0042620000 1 13 8461026023 1 14 0601823282 1 15 0018205020 1 15 0040005000 1 15B 0041205000 1 16 0010112020 1 16 0010112000 1 17 0601000209 1 18 17431014003 1 19 0072906321 1 20 0080000105 2 0343207250 2A 0043607000 3 C4130100203 3 1 7431323003 3 2 7431323123 3 3 7431323204 34 0061310080 3 4A 0030010000 3 48 0040010000 3 4C 0041210000 3 5 0017110020 4 8461315002 5 C4137000003 6 0012110075 6A 0042610000 6B 0041210000 T 0845044904 8 0016316045 8A 0040016000 8B 0041216000 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 65 PART NAME ROTORASSY FIELD ASSY RESISITOR INSULATOR WASHER INSULATOR WASHER FAN COUPLING RING HEX HEAD BOLT COUPLING DISK ASSY WASHER COUPLING HUB BALANCING PLATE
67. 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 600SSV is powered by a 4 cycle water cooled turbocharged VOLVO Model PENTA TAD1642GE Diesel Engine This engine is designed to meet every performance requirement for the generator Reference Table 2 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 Electronic 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 t
68. e and Outside 2 Add Supplemental Coolant Addatives SCAS to recharge the engine coolant 3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm 25 4 f blowby hose needs to be replaced ensure that the slope of the bloby hose is at least a 1 2 inch per foot with no sags or dips that could collect moisture and or oil AIR CLEANER General Inspection INDICATOR 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 14 as a general maintenance guideline Engine Side Refer to the Engine Instruction Manual Air Cleaner AIR CLEANER Every 250 hours Remove air cleaner element Figure 68 ELEMENT and clean the heavy duty paper element with light spray of Figure 68 Air Cleaner Indicator compressed air Replace the air cleaner as needed Air Cleaner with Dust Indicator This indicator Figure 65 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 PAGE 44 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 The air filter should not be changed until the indicator reads RED Dispose
69. ections 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 or oil lines are defective replace them immediately PAGE 38 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GEN START UP PROCEDURE MANUAL BEFORE STARTING AX CAUTION LETHAL EXHAUST HAZARD The engine s exhaust contains harmful emissions ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel If applicable perform the following Apply commercial power to the internal battery charger receptacle to ensure good starting via commercial power An external power cord will be required This capability is an option Apply commercial power to the jacket water heater receptacle not necessary for warm climates via commercial power An external power cord will be required This capability is an option Generator and Control Panel WARNING STARTING THE GENERATOR NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position 1 Pressthe main circuit breaker OFF switch Figure 40 MAIN CIRCUIT BREAKER OFF SWITCH Figure 40 Main Circuit Breaker OFF Switch 2 Verifythatthe main circuit breaker OFF lamp Figure 41 is lit ON
70. ehicle and is essential in the operation of the electric brakes on the trailer The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer Retractor Spring e VINN lt ej u Actuating Lever Hold Down Washer Self Adjusting Cable Adjuster Spring Adjuster Lever Adjuster Assembly Figure 72 Electric Brake Components Brake Drums or discs Linings and Hoses Brake drums or discs must not have cracks longer than one half the width of the friction area Linings must not be loose soaked with oil or grease or be dangerously thin Mechanical parts must be in place not broken or missing Check that all air hoses connected to the brake chambers are not worn or cut due to rubbing Air Leaks Always check for brake air leaks before towing the trailer NEVER tow the trailer with an brake air leak problem The possibility exists of brake failure Table 15 Electric Brake Troubleshooting Somon No Brakes Intermittent Weak Brakes or Brakes Pull to One Side Connections corroded Clean and correct cause of corrosion Locking Brakes Noisy Brakes PAGE 48 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV TRAILER MAINTENANCE 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
71. equence Check all wheel lug nuts periodically Table 17 Tire Torque Requirements FT LBS FT LBS FT LBS 8 LUG NUTS LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 71 Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts Use a torque wrench to tighten lug nuts PAGE 50 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE DOUBLE FILAMENT BULB CONNECT RIGHT TO CHASSIS TAIL LIGHT o SINGLE YELLOWIBROWN GREEN STOP amp TURN LEFT LICENSE TAIL LIGHT 1 i DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT 1 1 1 1 1 i DOUBLE i FILAMENT i BULB 1 RIGHT TO CHASSIS I TAIL LIGHT 280008 4 1 WHITE E WHITE COMMON GROUND SINGLE BACK BLUE TURN RIGHT FILAMENT Low GREEN TALL B LICENSE BULB YELLOW STOP RED TURN LEFT LICENSE TAIL LIGHT 1 DOUBLE i FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR CONNECTOR LEFT TAIL LIGHT i Figure 72 Trailer Wiring Diagram 5 Pin DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 51 DCA 600SSV TRAILER WIRING DIAGRAM TYPICAL 7 POLE TRAILER WIRE DIAGRAM TRAILER 0230 226 OO 666
72. flow air WARNING EXPLOSIVE FUEL 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 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 Gasoline is extremely flammable and is running or hot NEVER use fuel as a cleaning agent AX WARNING BURN HAZARDS Engine components can generate extreme 77 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 DANGER ELECTROCUTION HAZARDS During operation of this generator there exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even DEATH PAGE 8 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV SAFETY MESSAGE ALERT SYMBOLS WARNING ROTATING PARTS AX CAUTION RESPIRATORY HAZARDS MX NEVER operate equipment with covers BAO or guards removed Keep fingers hands ALWAYS wear approved respiratory hair and clothing away from all moving e protection parts to prevent injury AX CAUTION ACCIDENTAL STARTING AX CAUTION SIGHT AND HEARING HAZARDS ALWAYS wear ap
73. for details Do not remove cap f rad ator is hot B91110040 B90410010 P N B9511100404 P N B9504100104 SUPPORT HOOK Never use it for lifting the unit Use the LIFT HOOK on the roof for lifting 5 2257 13206 21504 Figure 2 Generator Decals PAGE 16 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR DECALS CIRCUIT BREAKER 5 3031 P N 08406 24504 AWARNING Only operate machine inwell ventilated areas Do notinhale exhaust gases DANGEROUS GAS P N B950420004 P N 0840625902 WARNING HOT PARTS can burn skin DIESEL FUEL can cause fire or explosion e Stop engine before fueling Keep cigarettes sparks and flame away Do not touch until the machine has suffic ent y cooled 6 0140 pu 890400030 P N 89504000304 P N 89504500004 B90450000 e L WARNING _ ELECTRIC SHOCK HAZARD Do not touch output terminals while this machine is operating Turn power off before servicing e Before connecting this generator to any buildings electrica system a censed electrician must install an isolation transfer switch e Serious injury or death may result w thout this transfer switch B93110050 B91110030 P N B9531100504 P N B9511100304 3 Phase output terminal Keep the loads balancing when using plural single loads 240 480V C05100040 GROUND 5 2635 P N C0551000404 P N 0840614104
74. g procedure 1 Place both the GFCI and AUX circuit breakers as shown in Figure 42 to the OFF position 2 Place the engine speed switch Figure 65 in the LOW down position PUSH TO STOP Figure 67 Emergency Stop Button LOW DOWN Figure 65 Engine Speed Switch Low 3 Let the engine cool by running it at low speed for 3 5 minutes with no load applied 4 Place the MPEC Control Switch Figure 66 in the OFF RESET LC MANUAL OFF RESET Figure 66 MPEC Control Switch Off Reset 5 Pressthe main circuit breaker OFF switch Figure 40 6 Verifythatthe main circuit breaker OFF lamp Figure 41 is lit ON 7 Verify that the all status LED on the MPEC display are OFF not lit 8 Remove all loads from the generator 9 Inspect entire generator for any damage or loosening of components that may have occured during operation DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 43 DCA 600SSV MAINTENANCE TABLE 14 INSPECTION MAINTENANCE 10 HS 250Hrs 500 _ 1000 Hrs Replace Engine Oil and Filter Clean Air Filter Change Fuel Filter Clean Radiator and Check Coolant Protection Level Replace Air Filter Element Check all Hoses and Clamps Clean Inside of Fuel Tank Measure Insulation Resistance Over 3M ohms GENERATOR Check Rotor Rear Support Bearing 1 Replace engine oil anf filter at 100 hours first time only Clean Unit Insid
75. he generator stop the engine and replace the air filter e AIR FILTER 3 4 10 11 Pre Heat Lamp Indicates that the glow plugs of the diesel engine are hot and the engine is ready to be started Emergency Stop Button Push this button inward to stop the engine in the event of an emergency DO NOT use this button as a normal means of stopping the engine Oil Pressure Gauge During normal operation this gauge be should read in the GREEN zone When starting the generator the oil pressure mar read a little bit higher but after the engine warms up the oil pressure should return to the green zone Water Temperature Gauge During normal operation this gauge be should read in the GREEN zone Fuel Level Gauge Indicates amount of diesel fuel remaining Battery Switch This switch should be set to the ON position during normal operation When the engine has been stop place this switch in the OFF position DO NOT turn this switch during normal operation it could cause damage to the electrical equipment Preheat Switch Press on to heat glow plugs in cold weather conditions Engine Speed Switch This switch changes the engine speed from idle to normal Hour Meter Switch Press this pushbutton switch to activate hour meter Indicates the number hours equipment has been in operational use DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 25 DCA 600SSV OUTP
76. here free flow of the air is restricted If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas DO NOT place hands or fingers inside generator engine compartment when engine is running NEVER run engine without air filter Severe engine damage may occur DO NOT leave the generator running in the manual mode unattended Refer to the VOLVO Engine Owner s Manual for engine technical questions or information 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 Q 3 A PAGE 10 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV RULES FOR SAFE OPERATION 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 The following safety recommendations should also be followed ALWAYS make sure generator is properly grounded NEVER use gas piping as an electrical ground ALWAYS make sure that electrical circuits are pr
77. his equipment Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others This Owner s Manual has been developed to provide complete instructions for the safe and efficient operation of the MQPower Model DCA 600SSV WHISPERWATT GENERATOR Before using this generator ensure that the operating individual has read and understands all instructions in this manual 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 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 WARNING LETHAL EXHAUST GASES 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
78. important the wheels tires and axle are properly matched AX CAUTION EYESIGHT HAZARD ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury 2n Z Z CAUTION REPAIRING TRAILER WHEELS 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 gt mD explode break off with great force and 7 cause serious eye or bodily injury 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 16 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury TABLE 16 TIRE WEAR TROUBLESHOOTING Over Inflation Under Inflation SOLUTION Adjust pressure to particular load per tire manufacturer Adjust pressure to particular load per tire manufacturer Make sure load does not exceed axle rating Align wheels WEAR PATTERN m Center Wear Edge Wear Side Wear Loss of camber or overloading Incorrect toe i
79. inals or to be switched off Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off Panel Light Switch When activated this switch will turn on the luminate the control panel Voltage Regulator Control Allows manual adjustment of the generator s output voltage PAGE 22 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR CONTROL PANEL 10 Circuit Breaker OFF Lamp When the circuit breaker ON switch is placed in the OFF position this lamp will be turned OFF 11 Circuit Breaker ON Lamp When the circuit breaker ON switch is placed in the ON position this lamp will be turned ON 12 Circuit Breaker OFF Switch Press this switch to place the 1600 amp circuit breaker in the open OFF position 13 Circuit Breaker ON Switch Press this switch to place the 1600 amp circuit breaker in the closed ON position 14 Auto On Off Engine Controller MPEC This controller has a vertical row of status LED s inset that when lit indicates that an engine malfunction fault has been detected When a fault OFF RESET has been detected the engine LOW OIL PRESSURE controller will evaluate the fault m qs and all major faults will shutdown the generator During cranking cycle The MPEC will attempt to crank the engine for 10 seconds
80. ine Operating Panels Figure 7 1 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 Engine Warning Display LED Module This module display s the following engine failures Overheat Lamp This lamp goes ON when the cooling water temperature rises abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown device will stop the engine automatically WATER TEMP Low Oil Pressure Lamp During normal operation of the generator this lamp should remain OFF When the Auto OFF Reset Manual switch is set to the Manual position to start the engine the lamp will illuminate After the oil pressure rises after start up the lamp will go OFF If this lamp is ever illuminated ON during normal operation of the generator the emergency shutdown device will stop the engine automatically PRESS Low Fuel Level Lamp When this lamp is ON itis time to stop the engine and add fuel Remember to let the engine cool before adding fuel o FUEL LEVEL Charge Lamp This lamp goes ON when the electrical charging system is not working properly E Clogged Air Filter Lamp This lamp goes ON when the air filter is clogged If this lamp goes ON during normal operation of t
81. ire 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 If wattage is not given on the equipment s name plate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 5 below when connecting loads Table 5 Power Factor By Load Type Of Load Single phase induction motors Electric heaters incandescent lamps Electronic devices communication equipment 16 Wire CAUTION Equipment damage can result from low voltage Three Phase Load When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 1 732 1000 Motors and motor driven equipment draw much greater current for starting than during operation 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 5 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 co
82. it breaker ON switch Figure 58 load applied When a load is applied the ammeter will indicate the amount of current that the load is drawing i from the generator ON SWITCH O Figure 58 Main Circuit Breaker ON Switch Figure 54 Ammeter No Load 21 Verify thatthe main circuit breaker ON lamp Figure 59 TNR is lit ON 17 The engine oil pressure gauge Figure 55 will indicate ON MAIN CIRCUIT the oil pressure kg cm of the engine Under normal operating conditions the pressure is approximately ENGINE OIL PRESSURE Figure 59 Main Circuit Breaker ON Lamp 22 Place the and aux circuit breakers Figure 60 in the Figure 55 Oil Pressure Gauge OFF position prior to starting the engine 18 The coolant temperature gauge Figure 56 will indicate CIRCUIT BREAKERS the coolant temperature Under normal operating FOR GFCI conditions the coolant temperature should be between RECEPTACLES 167 and 203 degrees Fahrenheit Green Zone Figure 56 Coolant Temperature Gauge CIRCUIT BREAKERS T FOR CS 6369 TWIST 19 The tachometer gauge Figure 57 will indicate the LOCK RECEPTACLES speed of the engine when the generator is operating Under normal operating conditions this speed is approximately 1800 RPM s Figure 60 GFCI and Auxiliary Circuit Breakers ON TACH HOUR S T Figure 57 Engine Tachometer Gauge DCA 600SSV OPERATION AND PARTS MANUAL REV 0
83. n Out of balance 91 Wheel lockup amp tire skidding Suspension Torsion axle systems the suspension takes place inside the square tube which is filled with highly resilient rubber It attaches directly to the trailer frame using brackets which are an integral part of the axle assembly See Figure 70 below Toe Wear Align wheels Check bearing adjustment Cupping and balance tires Avoid sudden stops when Flat Spots possible and adjust brakes Visually inspect the mounting hardware every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts immediately Torque torsion axle mounting hardware as recommended by manufactuer MOUNTING HARDWARE HARDWARE TORSION AXLE Figure 70 Major Suspension Components DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 49 DCA 600SSV TRAILER MAINTENANCE 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 71 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 17 3 After first road use retorque all lug nuts in s
84. nnecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used AX DANGER ELECTRICAL SYSTEM HAZARDS 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 If 3 load kVA is not given on the equipment nameplate approximate 30 load output maybe determined by multiplying voltage by amperage by 1 732 29 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR OUTPUTS Generator Output Voltages Maximum Amps A wide range of voltages are available to supply voltage for Table 8 shows the maximum amps the generator can pro many different applications Voltages are selected by apply vide DO NOT exceed the maximum amps as listed ing jumpers 6 to the voltage change over board Figure 15 To obtain some of the voltages as listed in Table 7 see below will require a fine adjustment using the voltage regu Table 8 Maximum Amps lator VR control knob located on the control panel Voltage Change Over Board The voltage change over board Figure 14 is located on the control box behind the generator control panel This bo
85. o a minimum Use the cable selection chart Table 6 as a guide for selecting proper extension cable size PAGE 20 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV MAJOR COMPONENTS Table 4 Generator Major Components NM _ Erare Ort anno Figure 5 Major Components DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 21 DCA 600SSV GENERATOR CONTROL PANEL D 3 Figure 6 Generator Control Panel The definitions below describe the controls and functions of the DCA 600SSV Control Panel Figure 6 1 Pilot Lamp Indicates that the generator is working properly Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When lit this light will make it easier to read the meters and gauges When the generator is not in use be sure to turn the panel light switch to the OFF position Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz AC Ammeter Indicates the amount of current the load is drawing from the generator AC Voltmeter Indicates the single phase output voltage present at the UVWO terminals 6 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 term
86. om dripping When detaching the filter for cleaning apply a piece P N 0800688504 of cloth or similar material to prevent oil from dripping Denyo Co Ltd S 544A P N 0800615102 Figure 2 Generator Decals PAGE 14 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR DECALS SAFETY INSTRUCTIONS Improper operation of this machine can cause severe injury or death Read the instruction manual carefully before operating or servicing This machine should only be operated by a person with sufficient knowledge and skill to ensure safe operation WHISPERWATT 600 POWER CORP gt WHISPERWATT 600 POWER 60 KVA AC GENERATOR MODEL DCA 600SSK C56110090 High voltage circuits are located inside the output terminal cover and control panel Close the cover and control panel before operating Moving parts and hot surfaces are contained within the enclosure Close all doors and lock them before operating B92110040 P N B9521100404 TERMINAL COVER STOPPER 4 WHEN COVER IS CLOSE OR MOVING ENGINE SPEED WHEN COVER IS 55 P N 9039208704 5 4516 P N 08406557 04 COOLING WATER Be sure to operate this machine with its radiator cap completely secured Replace the cap with a new P N 9039208694 one when damaged or deformed S 961 P N 0800689204 Precautions on handling the oil drain pump 1 Handling procedures Connect an oil discharging hose
87. om the recovery tank When adding coolant to the radiator DO NOT remove the radiator cap until the unit has completely cooled See Table 10 for engine and radiator coolant capacities Make sure the coolant level in the recovery tank is always between the and the L markings Table 10 Coolant Capacity Engine and Radiator 24 6 Gal 93 0 Liters gt Quan 19 Ur Operation Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 11 has been added Table 11 Anti Freeze Operating Temperatures Freezing Point Boiling Point Vol Anti Freeze DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 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 Volvo 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 Volvo Engine Owner s Manual The fan belt tension is proper if the fan belt
88. operly grounded per the National Electrical Code NEC and local codes before operating generator Severe injury or DEATH by electrocution can result from operating an ungrounded generator ALWAYS be sure to use the ground terminal green wire when connecting a load to the U V and W output terminal lugs Electrical Safety ALWAYS have qualified electrician perform the generator wiring installation ALWAYS make sure generator installation is accordance with the National Electrical Code NEC and local codes before operating generator 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 extension cord has been selected for the job See Table 5 NEVER power cables or cords lay in water NEVER stand in waterwhile AC power from the generator is being transfer to a load A DANGER ELECTROCUTION HAZARDS During operation of this generator 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 or worn cables when connecting equipment to the generator Make sure power connecting cables are securely connected to the generators output terminals insufficient tightening of the terminal connections may cause damage to the generator and ele
89. 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 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 19 DCA 600SSV GENERAL INFORMATION DCA 600SSVWhisperwatt Series Familiarization Generator The MQ Power Model DCA 600SSV is a 528 kW generator Figure 5 that is designed as a high quality portable requires atrailer 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 Hour Meter Gauge Water Temperature Gauge Water Temp Alarm Lamp Oil Pressure Gauge Oil Pressure Alarm Lamp Charging Alarm Lamp Fuel Level Gauge Low Fuel Warning Alarm Lamp Pre Heat Button Pre Heat Lamp Air Filter Alarm Lamp Engine Speed Switch Battery Switch Emergency Stop Button Generator Control Panel The Generator Control Panel is provided with the following Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change O
90. ow 10 Place the Auto Off Reset Manual switch in the Manual position to start the engine Figure 48 Once the engine starts let the engine run for 1 2 minutes Listen for any abnormal noises AUTO MANUAL OFF RESET Figure 48 Auto Off Reset Manual Switch 11 Once the engine is warm and the engine is running properly place the engine speed switch in the HIGH position Figure 49 HIGH UP LOW DOWN Figure 49 Engine Speed Switch High 12 Verify that the Engine Running status LED on the MPEC unit Figure 50 is ON lit after the engine has been started MANUAL OFF RESET LOWOIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING Figure 50 Engine Running LED ON 13 The generator s frequency meter Figure 51 should be displaying the 60 cycle output frequency in HERTZ Figure 51 Frequency Meter Hz 14 The generator s AC voltmeter Figure 52 will display the generator s output in VOLTS Figure 52 AC Voltmeter 15 If the voltage is not within the specified tolerance use the voltage adjustment control knob Figure 53 to increase or decrease the desired voltage INCREASE DECREASE Figure 53 Voltage Adjust Control Knob PAGE 40 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV GENERATOR START UP PROCEDURE MANUAL 16 The ammeter Figure 54 will indicate zero amps with no 20 Press the main circu
91. proved eye and OFF ALWAYS place the Engine ON OFF gt 34 hearing protection switch in the OFF position and remove the ignition key when the pump is not in Use AX CAUTION OVER SPEED CONDITIONS CAUTION EQUIPMENT DAMAGE MESSAGES NEVER tamper with the factory settings Other important messages are provided throughout this of the engine governor or settings manual to help prevent damage to your generator other Personal injury and damage to the engine property or the surrounding environment or equipment can result if operating in speed ranges above maximum allowable This generator other property or the surrounding environment could be damaged if you do not follow instructions DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 9 DCA 600SSV RULES FOR SAFE OPERATION AX DANGER READ THIS MANUAL 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 The following safety guidelines should always be used when operating the DCA 600SSV Whisperwatt Generator General Safety DO NOT operate or service this 42 equipment before reading this entire 4 manual The operator MUST BE familiar with proper safety precautions and operations techniques before using generator This equipment should not be operated by
92. provide more or less braking force thus easing the brake load on the towing vehicle W Brake system has very little lag time between the time the vehicle s brakes are actuated and the trailer s brakes are actuated Brake system can provide an independent emergency brake system Remember in order to properly synchronize the tow vehicle s braking to the trailer s braking can only be accomplished by road testing Brake lockup grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under adjusted brakes Before any brake synchronizations adjustments can be made the trailer brakes should be burnished in by applying the brakes 20 30 times with approximately a 20 m p h de crease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes to slightly be seated into the brake drum sur face Figure 72 displays the major electric brake components that will require inspection and maintenance Please inspect these components as required See Table 15 Electric Brake Troubleshooting Magnets For All Electric Brakes To make certain an electrically operated braking system will function properly you must have your dealer inspect the magnets at least once a year or each 12 000 miles See the brake manual for wear and current inspection instruc tions Brake Controller The electric brake controller is part of the tow v
93. quently to prevent engine malfunction A WARNING BURN 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 7 and generator to cool before performing maintenance Radiator 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 Battery Safety Use the following guidelines when handling the battery The battery contains acids that can cause injury to the eyes and skin To gt avoid eye irritation always wear safety glasses M Use well insulated gloves when picking up the battery DANGER EXPLOSION HAZARDS The risk of an explosion exists when performing service on the battery To avoid severe injury or DEATH 8 DO NOT drop the battery There is the possibili
94. requirements of the UVWO terminals 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 120 VAC GF C l RECEPTACLE uj BUTTON TEST BUTTON Figure 9 G F C I Receptacle Twist Lock Dual Voltage 240 139 VAC Receptacles There are three 240 139 VAC 50 amp auxiliary twist lock CS 6369 receptacles Figure 10 provided on the output terminal panel These receptacles can be accessed in any voltage change over board position 5 6369 TWIST LOCK RECEPTACLES Figure 10 240 139 VAC Twist Lock Auxiliary Receptacles Each auxiliary 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 UVWO terminals Turn the voltage regulator control knob Figure 11 on the control panel to obtain the desired voltage Turning the knob clockwise will increasethe voltage turning the knob counter clockwise will decrease the voltage INCREASE DECREASE Figure 11 Voltage Regulator Control Knob DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 27 DCA 600SSV OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Loads can be connected to the generator by the UVWO
95. t positions that provide 6 different output voltages at the UVWO output terminals The generator is shipped from the factory in the 240V configuration The voltage regulator VR allows the user to increase or decrease the selected voltage 30 240V UVWO Terminal Output Voltages 1 Jumperthe voltage change over board for 240V operation as shown in Figure 20 JUMPER 6 PLACES Figure 20 Voltage Change Over Board 240V Configuration 2 Connectthe load wires to the UVWO terminals as shown in Figure 21 GREEN GROUND CONNECTION MUST BE USED AT ALL TIMES THREE PHASE 240 VAC LOAD CONNECTIONS Figure 21 UVWO Terminal Lugs 3 240V Connections 3 Turnthe voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required INCREASE DECREASE Figure 22 Voltage Regulator Knob 10 240V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 240V operation as shown in Figure 20 2 Connecttheload wires to the UVWO terminals as shown in Figure 23 GROUND CONNECTION MUST BE USED AT ALL TIMES SINGLE PHASE 240 VAC LOAD CONNECTIONS Figure 23 UVWO Terminal Lugs 10 240V Connections 10 139V UVWO Terminal Output Voltages 1 Make sure the voltage change over board is jumpered for 240V operation as shown in Figure 2
96. tallation 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 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 mm or larger b Aluminum 8 AWG 8 4 mm
97. tank lining for signs of excessive amounts of oil or other foreign matter 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 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 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 45 DCA 600SSV MAINTENANCE 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
98. terminal lugs or the convenience receptacles See Figure 12 Make sure to read the operation manual before attempting to connect aload to the generator To protect the UVWO output terminals from overload a 3 pole 1 600 amp main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine CS 6369 TWIST LOCK RECEPTACLES VOLTAGE OUTPUT TERMINALS Figure 12 Connecting Loads Over Current Relay An over current relay Figure 13 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 13 Over Current Relay Maximum Power Output KW The entire load connected to the UVWO output terminal lugs duplex and auxiliary receptacles must not exceed 528 kW in standby or 480 kW in prime output PAGE 28 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage and frequency 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 requ
99. the generator is operating in a normal maner the following code Figure 82 should be displayed once the reset button is pressed and released NO BLINK FOR 2 SECONDS LAMP FLASHES ONCE 7 G LAMP FLASHES ONCE Figure 82 Normal Operating Code For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruction manual When the MPEC Control Switch is placed in the AUTO position the same error codes will apply Codes will not be active until the unit is activated PAGE 60 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 NOTE PAGE DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 PAGE 61 DCA 600SSV 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 The contents and part numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availibility of the parts listed Sample Parts List NO PARTNO PART NAME QTY REMARKS 1 12345 oes 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
100. tled 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 willbe accepted and credit willbe allowed subject to the following provi sions 1 AReturned Material Authorization must be approved by Multiquip prior to ship ment 2 ToobtainaReturn Material Authorization alistmustbe providedto Multiquip Parts Salesthatdefines item numbers quanti ties and descriptions of the items to be returned Theparts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated c The list must state the reason s for the return d The list must reference the sales order s orinvoice s under which the items were originally purchased e The list must include the name and phone number ofthe person request ing the RMA 3 Acopy ofthe Return Material Authoriza tionmustaccompany the return shipment 4 Freight is at the sender s expense All parts mustbe returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip pack age if any and with Multiquip part numbers clearly marked Thefollowingitems are not returnable a Obsolete parts If an item is in the price book and shows
101. ty 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 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 Incase 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 PAGE 12 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV RULES FOR SAFE OPERATION Towing amp 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 AX CAUTION FOLL
102. umn 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 ona specific model or model number variant Indicated by ONLY NOT USED ON 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 PAGE 62 DCA 600SSV OPERATION AND PARTS MANUAL REV 0 07 13 09 DCA 600SSV SUGGESTED SPARE PARTS DCA 600SSV w SA6D170AE 1 VOLVO ENGINE 1 to 3 Units Qty P N Description 61258170392 AIR FILTER INNER amp OUTER wv 6003117111 FUEL FILTER 6002111231
103. ver Switch Voltmeter Change Over Switch Voltage Regulator Panel Light Panel Light Switch 3 Pole 1 600 amp Main Circuit Breaker Engine Control Unit Computer Controlled Control Box Located Behind Gen Control Panel Automatic Voltage Regulator Current Transformer Over Current Relay Voltage Rectifer Starter Relay Voltage Change over Board Output Terminal Panel The Output Terminal Panel is provided with the following Three 120 240V output receptacles CS 6369 50A Three auxilliary circuit breakers 50A Two 120V output receptacles GFCI 20A Two GFCI circuit breakers 20A Four output terminal boards 30 power Ground terminal Battery Charger Optional Water Heater Optional Open Delta Excitation System The DCA 600SSV 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

Multiquip DCA-600SSV Portable Generator User Manual

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