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Multiquip operation manual Operation And Parts Manual, MODEL DCA-600SSK, Whisperwatt Series

Models: DCA-600SSK

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OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA-600SSK

60 Hz GENERATOR

(KOMATSU SA6D170AE-1 DIESEL ENGINE)

PARTS LIST NO. C4875300104C

SERIAL NO. 3692434~

Revision #7 (04/30/10)

To find the latest revision of this publication, visit our website at: www.mqpower.com

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.

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Multiquip operation manual Operation And Parts Manual, KOMATSU SA6D170AE-1 DIESEL ENGINE, MODEL DCA-600SSK

Contents

KOMATSU SA6D170AE-1 DIESEL ENGINE OPERATION AND PARTS MANUALPARTS LIST NO. C4875300104C SERIAL NO. 3692434~ MODEL DCA-600SSKDiesel engine exhaust and some of PROPOSITION 65WARNINGDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE NOTE PAGETABLE OF CONTENTS MQ Power DCA-600SSK AC GeneratorSpecification and part COMPONENT DRAWINGSWhen ordering parts, please supply PARTS ORDERING PROCEDURESChoose from three easy options PartsTable 1. Generator Specifications DCA-600SSK - SPECIFICATIONSTable 2. Engine Specifications 3/4 loadDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE NOTE PAGEFigure 1. Dimensions DCA-600SSK - DIMENSIONS TOP AND SIDEFigure 2. Dimensions DCA-600SSK - DIMENSIONS FRONT , REAR AND DOORSDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE HAZARD SYMBOLS DCA-600SSK - SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERWARNING - ROTATING PARTS DCA-600SSK - SAFETY MESSAGE ALERT SYMBOLSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDCA-600SSK - RULES FOR SAFE OPERATION General SafetyDANGER - READTHIS MANUAL DCA-600SSK - RULES FOR SAFE OPERATION Electrical SafetyGenerator Grounding DANGER - ELECTROCUTION HAZARDSBattery Safety Maintenance SafetyDCA-600SSK- RULES FOR SAFE OPERATION DANGER - EXPLOSION HAZARDSDCA-600SSK - RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies Figure 3. Typical Generator Grounding Application DCA-600SSK - INSTALLATIONOutdoor Installation DCA-600SSK - INSTALLATIONCAUTION - EXHAUST HAZARD MountingDCA-600SSK -TOWING RULES FOR SAFE OPERATION Towing Safety PrecautionsCAUTION -TOWING REGULATIONS Figure 4. Generator and TrailerExplanation of Chart DCA-600SSK - TRAILER-SAFETY GUIDELINESCAUTION - TRAILER INSPECTION Table 3. Trailer Specifications DCA-600SSK -TRAILER-SPECIFICATIONSMODEL FUEL CELLTable 3. Specifications Cont DCA-600SSK -TRAILER-SPECIFICATIONSDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE MODELMachine Safety Decals DCA-600SSK - OPERATION AND SAFETY DECALSDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - OPERATION AND SAFETY DECALSDCA-600SSK - OPERATION AND SAFETY DECALS DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - OPERATION AND SAFETY DECALSDCA-600SSK - GENERAL INFORMATION Microprocessor Controlled Alarm SystemDCA-600SSK FAMILIARIZATION Generator Engine Control PanelTable 4. Generator Major Components DCA-600SSK - MAJOR COMPONENTSDESCRIPTION DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEUp to S/N S/N 3698617~ Figure 6. Generator Control Panel DCA-600SSK - GENERATOR CONTROL PANELDCA-600SSK - GENERATOR CONTROL PANEL Up to S/N S/N 3698617~ Figure 7. Engine Operating Panels DCA-600SSK - ENGINE OPERATING PANEL8. Fuel Level Gauge - Indicates amount of diesel fuel remaining DCA-600SSK - ENGINE OPERATING PANELDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE Output Terminal Familiarization DCA-600SSK - OUTPUTTERMINAL OVERVIEWThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal PanelDCA-600SSK - OUTPUT TERMINAL PANEL OVERVIEW Access to UVWO Terminals120VAC GFCI Receptacles Figure 9. G.F.C.I. ReceptacleMaximum Power Output KW Connecting LoadsDCA-600SSK - OUTPUT TERMINAL PANEL OVERVIEW Over Current RelayThree Phase Load Single Phase LoadDCA-600SSK- LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSTable 9. Generator Ampere Ratings - 3Ø DCA-600SSK - GENERATOR OUTPUTSTable 7. Generator Available Voltages Generator OutputVoltagesDCA-600SSK - GENERATOR OUTPUTS/GAUGE READING How to Read the Output Terminal GaugeMaximum Amps Figure 19. AC Ammeter Change-Over SwitchUVWO Terminal Output Voltages DCA-600SSK - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages3Ø-480V UVWO Terminal Output Voltages DCA-600SSK - OUTPUT TERMINAL PANEL CONNECTIONS1Ø-480V UVWO Terminal Output Voltages 1Ø-277V UVWO Terminal Output VoltagesTable 11. Recommended Motor Oil DCA-600SSK - PRE-SETUPCircuit Breakers Lubrication OilCAUTION -TRAILER FUELTANK Refueling ProcedureWARNING - RESPIRATORY HAZARDS refuelingCAUTION - REFUELINGTHE GENERATOR DCA-600SSK - PRE-SETUPFigure 35. Full Trailer Tank Figure 37. Full Fuel SystemCleaning the Radiator DCA-600SSK- PRE-SETUPAir Cleaner Table 12. Coolant CapacityBattery Cable Installation BatteryCAUTION - BATTERY SERVICING SAFETY WiringBEFORE STARTING DCA-600SSK - GEN. START-UP PROCEDURE MANUALCAUTION - LETHAL EXHAUST HAZARD Generator and Control Panel5. Set the battery ON/OFF switch Figure 45 to the “ON” position DCA-600SSK- GENERATOR START-UP PROCEDURE MANUAL8. Place the engine throttle lever in the “LOW” position Figure Figure 55. Coolant Temperature Gauge DCA-600SSK- GENERATOR START-UP PROCEDURE MANUALFigure 54. Oil Pressure Gauge Figure 57. Main, Aux. and GFCI Circuit Breakers ON20. Set the battery ON/OFF switch Figure 60 to the “ON” position DCA-600SSK - GENERATOR START-UP PROCEDURE MANUALBEFORE STARTING Generator and Control PanelCAUTION - ENGINE SPEED SWITCH DCA-600SSK - GENERATOR START-UP PROCEDURE AUTO MODECAUTION - BACKUP GENERATOR USE WARNING - AUTO MODE MAINTENANCEEmergency Shutdown Procedure DCA-600SSK - GENERATOR SHUT-DOWN PROCEDURECAUTION - EMERGENCY STOP SWITCH Engine Shutdown Controller S/N 3698617~INSPECTION / MAINTENANCE DCA-600SSK - MAINTENANCEENGINE DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGECleaning the Fuel Strainer Service DailyGeneral Inspection Outer ElementChanging Oil Flushing Out Radiator and Changing CoolantReplacing Fuel Filter DCA-600SSK - MAINTENANCEGreasing Cleaning Breather ElementGenerator Storage Removal From Long Term StorageNOTEapplied to the generators internal battery charger DCA-600SSK - MAINTENANCEFigure 75. Battery Charger/Jacket Water Heater Power Connections DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEBrakes DCA-600SSK -TRAILER BRAKES MAINTENANCEAir Brake System S-Cam BrakesTires/Wheels/Lug Nuts DCA-600SSK -TRAILER MAINTENANCECAUTION - EYESIGHT HAZARD Tire Wear/InflationLug Nut Torque Requirements DCA-600SSK -TRAILER MAINTENANCEFigure 78. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsFigure 79. Trailer Wiring Diagram 5-Pin DCA-600SSK -TRAILER-WIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE Figure 80. Trailer Wiring Diagram 7-Pin DCA-600SSK -TRAILER-WIRING DIAGRAMFigure 81. Generator Wiring Diagram DCA-600SSK -GENERATORWIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE Figure 82. Main Circuit Breaker Wiring Diagram DCA-600SSK - GENERATOR WIRING DIAGRAM MAIN BREAKERFigure 83. Engine Wiring Diagram DCA-600SSK - ENGINE WIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE Figure 84. Engine Wiring DiagramContinued DCA-600SSK - ENGINE WIRING DIAGRAMFigure 85. Electronic Governor Controller DCA-600SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE TABLE 20. ENGINE TROUBLESHOOTING DCA-600SSK -TROUBLESHOOTING ENGINESYMPTOM POSSIBLE PROBLEMTABLE 20. ENGINE TROUBLESHOOTING CONTINUED DCA-600SSK -TROUBLESHOOTING ENGINESYMPTOM POSSIBLE PROBLEMTABLE 21. GENERATOR TROUBLESHOOTING DCA-600SSK -TROUBLESHOOTING GENERATOR/ENGINESYMPTOM POSSIBLE PROBLEMTABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-600SSK -TROUBLESHOOTING MPECSolution SymptonSAMPLE PARTS LIST EXPLANATION OF CODE IN REMARKS COLUMNQTY. Column NO. ColumnDCA-600SSK w/SA6D170AE-1 KOMATSU ENGINE DCA-600SSK - SUGGESTED SPARE PARTS1 to 3 Units DescriptionGENERATOR ASSY DCA-600SSK - GENERATOR ASSYREMARKS PART NAMEDCA-600SSK - GENERATOR ASSY INCLUDE ITEMS WDCA-600SSK - GENERATOR ASSY PART NAME DCA-600SSK - GENERATOR ASSYREMARKS CONTROL BOX ASSY DCA-600SSK - CONTROL BOX ASSYPART NAME DCA-600SSK - CONTROL BOX ASSYREMARKS REPLACESDCA-600SSK - CONTROL BOX ASSY DCA-600SSK - CONTROL BOX ASSY CHANGE-OVER SWITCH, AMMETERPART NAME REMARKSDCA-600SSK - CONTROL BOX ASSY PART NAME DCA-600SSK - CONTROL BOX ASSY. S/N 3692433 AND BELOWREMARKS DCA-600SSK - CONTROL BOX ASSY PART NAME DCA-600SSK - CONTROL BOX ASSYREMARKS ENGINE & RADIATOR ASSY DCA-600SSK - ENGINE & RADIATOR ASSYPART NAME DCA-600SSK - ENGINE & RADIATOR ASSYREMARKS DCA-600SSK - ENGINE & RADIATOR ASSY PART NAME DCA-600SSK - ENGINE & RADIATOR ASSYREMARKS ENGINE OPERATING PANEL ASSY DCA-600SSK - ENGINE OPERATING PANEL ASSYPART NAME DCA-600SSK - ENGINE OPERATING PANEL ASSYREMARKS S/N 3698617 AND ABOVEOUTPUT TERMINAL ASSY DCA-600SSK - OUTPUTTERMINAL ASSYPART NAME DCA-600SSK - OUTPUTTERMINAL ASSYREMARKS SET BOARD, OUTPUT TERMINALDCA-600SSK - OUTPUTTERMINAL ASSY PART NAME DCA-600SSK - OUTPUTTERMINAL ASSYREMARKS BATTERY ASSY DCA-600SSK - BATTERY ASSYPART NAME DCA-600SSK - BATTERY ASSYREMARKS MUFFLER ASSY DCA-600SSK - MUFFLER ASSYPART NAME DCA-600SSK - MUFFLER ASSYREMARKS FUEL TANK ASSY DCA-600SSK - FUELTANK ASSYPART NAME DCA-600SSK - FUELTANK ASSYREMARKS THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-600SSK - ENCLOSURE #1 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - ENCLOSURE #1 ASSYPART NAME REMARKSTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-600SSK - ENCLOSURE #2 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-600SSK - ENCLOSURE #2 ASSYREMARKS ENCLOSURE #2 ASSYDCA-600SSK - ENCLOSURE #2 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-600SSK - ENCLOSURE #2 ASSYREMARKS THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-600SSK - ENCLOSURE #3 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYPART NAME DCA-600SSK - ENCLOSURE #3 ASSYREMARKS RUBBER SEAL ASSY DCA-600SSK - RUBBER SEAL ASSYPART NAME DCA-600SSK - RUBBER SEAL ASSYNAME PLATE AND DECALS DCA-600SSK - NAMEPLATE AND DECALSENGINE OPERATING PANEL GROUP CONTROL BOX GROUPDCA-600SSK - NAMEPLATE AND DECALS PART NAMEDCA-600SSK - NAMEPLATE AND DECALS PART NAME DCA-600SSK - NAMEPLATE AND DECALSREMARKS OUTPUTTERMINAL GROUPEffective October 1 TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE NOTE PAGE18910 Wilmington Ave Contact mqpower@multiquip.comCarson, CA Contact mq@multiquip.com