Multiquip DCA-600SSV operation manual Maintenance Safety, Battery Safety

Page 12

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 frequently to prevent engine malfunction.

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 and generator to cool before performing maintenance.

Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Battery Safety

Use the following guidelines when handling the battery:

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid severe injury or DEATH:

DO NOT drop the battery.There is the possibility of risk that the battery may explode.

DO NOT expose the battery to open flames, sparks, cigarettes

etc.The battery 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.

In case the battery liquid (dilute sulfuric acid) comes in contact with your EYES, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

PAGE 12 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

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Contents Model DCA-600SSV Proposition 65WARNING Reporting Safety Defects AdministratorTable of Contents Parts Ordering Procedures Ordering parts has never been easierDCA-600SSV Specifications DCA-600SSV Dimensions TOP, Side and Front DimensionsDCA-600SSV Safety Message Alert Symbols Hazard SymbolsDCA-600SSV Safety Message Alert Symbols This generator, other propertyGeneral Safety BurnsElectrical Safety DCA-600SSV Rules for Safe OperationGenerator Grounding Maintenance Safety Battery SafetyTowing & Transporting Safety DCA-600SSV Rules for Safe OperationEmergencies Machine Safety Decals DCA-600SSV Generator DecalsDCA-600SSV Generator Decals 16 DCA-600SSV Operation and Parts Manual REV. #0 07/13/09 DCA-600SSV Generator Decals DCA-600SSV Installation Typical Generator Grounding ApplicationOutdoor Installation MountingDCA-600SSV General Information DCA-600SSV Major Components Generator Major ComponentsDCA-600SSV Generator Control Panel Pilot Lamp Indicates that the generator is working properlyWhen the circuit DCA-600SSV Generator Control PanelLamp will be turned OFF Be turned onDCA-600SSV Engine Operating Panel DCA-600SSV Engine Operating Panel Will stop the engine automaticallyDCA-600SSV Outputterminal Familiarization Output Terminal FamiliarizationDCA-600SSV Output Terminal Panel Familiarization 120VAC Gfci ReceptaclesConnecting Loads Maximum Power Output KWDCA-600SSV Output Terminal Panel Familiarization Over Current RelaySingle Phase Load Three Phase LoadDCA-600SSV- Load Application Generator OutputVoltages Voltage Change-Over BoardMaximum Amps Rated Maximum AmpsDCA-600SSV Generator OUTPUTS/GAUGE Reading AC Ammeter Gauge ReadingACVoltmeter Gauge Reading DCA-600SSV Output Terminal Panel Connections Uvwo Terminal Output Voltages3Ø-240V Uvwo Terminal Output Voltages 1Ø-240V Uvwo Terminal Output VoltagesDCA-600SSV Output Terminal Panel Connections 3Ø-480V Uvwo Terminal Output Voltages1Ø-480V Uvwo Terminal Output Voltages 1Ø-277V Uvwo Terminal Output VoltagesDCA-600SSV Setup Circuit BreakersLubrication Oil Refueling Procedure RefuelingFuel from the secondary inner 36 DCA-600SSV Operation and Parts Manual REV. #0 07/13/09 DCA-600SSV- Setup Cleaning the RadiatorAir Cleaner Fan Belt Tension Operation Freezing WeatherBattery Battery Cable InstallationWiring AlternatorDCA-600SSV GEN. START-UP Procedure Manual Generator and Control PanelDCA-600SSV- Generator START-UP Procedure Manual Place the engine speed switch in the LOW position FigureDCA-600SSV- Generator START-UP Procedure Manual Verify that the main circuit breaker on lamp is lit onDCA-600SSV Generator START-UP Procedure Auto Mode Set the engine speed switch to the High positionDCA-600SSV Generator SHUT-DOWN Procedure Normal Shutdown ProcedureEmergency Shutdown Procedure DCA-600SSV Maintenance Air CleanerAir Cleaner with Dust Indicator General InspectionService Daily Cleaning Inside the Fuel TankCleaning the Fuel Strainer Fuel AdditionRadiator Cleaning Air RemovalCheck Oil Level Replacing Oil FilterBattery Charger & Jacket Water Heater Power Connections To ensure adequate startingDCA-600SSV -TRAILER Brakes Maintenance DCA-600SSV -TRAILER Maintenance Tires/Wheels/Lug NutsTire Wear/Inflation SuspensionLug Nut Torque Requirements Start all wheel lug nuts by handLug nuts DCA-600SSV -TRAILER-WIRING Diagram Trailer Wiring Diagram 5-PinDCA-600SSV -TRAILER-WIRING Diagram DCA-600SSV -GENERATORWIRING Diagram Generator Wiring DiagramDCA-600SSV Generator Wiring Diagram Main Breaker Main Circuit Breaker Wiring DiagramDCA-600SSV Enginewiring Diagram DCA-600SSV -TROUBLESHOOTING Engine DCA-600SSV -TROUBLESHOOTING Engine SmoothDCA-600SSV -TROUBLESHOOTING Generator Generator TroubleshootingDCA-600SSV -TROUBLESHOOTING Engine Controller Engine Controller Troubleshooting MpecDCA-600SSV-TROUBLESHOOTING Diagnostic Lamp Example Error CodeMethod of Operation For a complete understandingDCA-600SSV Operation and Parts Manual REV. #0 07/13/09 Sample Parts List DCA-600SSV- Explanation of Code in Remarks ColumnDCA-600SSV Suggested Spare Parts DCA-600SSV w/SA6D170AE-1VOLVO EngineQty Description DCA-600SSV Generator Assy 0601842366 81710200048171020504 8461070002DCA-600SSV Generator ASSY. 7431310003 84613120040016308095 11A 0040008000DCA-600SSV Control BOX Assy C4214001602 06018061530017108020 C4261506003DCA-600SSV Control BOX ASSY. 39-C 0041214000 74318611137431852104 001710803572 DCA-600SSV Operation and Parts Manual REV. #0 07/13/09 0605010502 8481814503C4214300904 0601850349DCA-600SSV Engine and Radiator Assy C4924200284 06020152400602015241 0602046623DCA-600SSV Engine and Radiator ASSY. 0150000018 00192060250130404000 0130204000DCA-600SSV Engine Operating Panel Assy C4484002102 0017112030C4352102203 8085182004DCA-600SSV Outputterminal Assy C4231700603 75218605047521850504 0010112040DCA-600SSV Outputterminal ASSY. C3261600704 32-1 02212001500017106030 0601812598DCA-600SSV Battery Assy 0168719052 C91091007040805007804 0805006504DCA-600SSV Muffler Assy C4331100802 0019210020C4334200904 0019210030DCA-600SSV Fueltank Assy C4364002203 08455001040810105400 0264100505DCA-600SSV Enclosure #1 Assy C4414003302 3875116304C4414100204 C4414100304DCA-600SSV Enclosure #1 ASSY. 35A 0030020000 35B 004002000035C 0041220000 C4434200103DCA-600SSV Enclosure #2 Assy C4444001303 38751510040207106000 C4444000103DCA-600SSV Enclosure #2 ASSY. C4464202403 42A C4494501604C4464202503 43A C4494501604DCA-600SSV Enclosure #3 Assy C4454206003 00191100700042310000 0042410000DCA-600SSV Rubber Seal Assy 0229201650 02289014400228901670 0228901020DCA-600SSV Nameplate and Decals 0800520100 08005209040800520814 0800564004104 DCA-600SSV Operation and Parts Manual REV. #0 07/13/09 1320620904 63606200040840607104 0800615102Terms and Conditions of Sale Parts FreightpolicyDCA-600SSV Operation and Parts Manual REV. #0 07/13/09 Heres HOW to GET Help