Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip MQ Power DCA-600SSK AC Generator, Table Of Contents, Component Drawings, 72-75

Models: DCA-600SSK

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MQ Power DCA-600SSK AC Generator

MQ Power DCA-600SSK AC Generator

Proposition 65 Warning	2
Parts Ordering Procedures	5
Specifications Generator/Engine	6
Dimensions (Top and Side)	8
Dimensions (Front and Rear)	9
Safety Alert Messages Symbols	10-11
Rules for Safe Operation	12-15
Installation	16-17
Towing Rules for Safe Operation	18
Trailer Safety Guidelines	19
Trailer Specifications	20-21
Operation and Safety Decals	22-25
General Information	26
Major Components	27
Generator Control Panel (Up to S/N 3698616)	28
Generator Control Panel (S/N 3698617~)	28
Generator Control Panel Description	29
Engine Operating Panel (Up to S/N 3698616)	30
Engine Operating Panel (S/N 3698617~)	30
Engine Operating Panel Description	31
Output Terminal Panel Overview	32-34
Load Application	35
Generator Outputs	36
Generator Outputs/Gauge Reading	37
Output Terminal Panel Connections	38-39
Pre Setup	40-44
Generator Start-up Procedure (Key Switch)	45-47
Generator Start-up Procedure ( Manual MPEC)	48
Generator Start-up Procedure (Auto MPEC)	49
Generator Shutdown Procedure	50
Maintenance	51-55
Trailer Brakes Maintenance	56
Trailer Maintenance	57-58
Trailer Wiring Diagrams	59-60
Generator Wiring Diagram	61
Generator Main Breaker Wiring Diagram	62
Engine Wiring Diagrams	63-64
Electronic Governor Controller Wiring Diagram	65
Engine Troubleshooting	66-67
Generator Troubleshooting	68
Engine Contoller Troubleshooting (MPEC)	69
Explanation of Codes in Remarks Column	70

TABLE OF CONTENTS

COMPONENT DRAWINGS

Generator Assembly	72-75
Control Box Assembly	76-83
Engine Radiator Assembly	84-87
Engine Operating Panel Assembly	88-89
Output Terminal Assembly	90-93
Battery Assembly	94-95
Muffler Assembly	96-97
Fuel Tank Assembly	98-99
Enclosure #1 Assembly	100-101
Enclosure #2 Assembly	102-105
Enclosure #3 Assembly	106-107
Enclosure (Rubber Seals)	108-109
Name Plate and Decals	110-113
Terms and Conditions Of Sale — Parts	114

Specification and part

NOTE number are subject to change without notice.

PAGE 4 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)

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Multiquip MQ Power DCA-600SSK AC Generator, Table Of Contents, Component Drawings, 72-75, 76-83, 84-87, 88-89, 90-93

Contents

OPERATION AND PARTS MANUAL KOMATSU SA6D170AE-1 DIESEL ENGINEPARTS LIST NO. C4875300104C SERIAL NO. 3692434~ MODEL DCA-600SSKPROPOSITION 65WARNING Diesel engine exhaust and some ofNOTE PAGE DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEMQ Power DCA-600SSK AC Generator TABLE OF CONTENTSSpecification and part COMPONENT DRAWINGSPARTS ORDERING PROCEDURES When ordering parts, please supplyChoose from three easy options PartsDCA-600SSK - SPECIFICATIONS Table 1. Generator SpecificationsTable 2. Engine Specifications 3/4 loadNOTE PAGE DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEDCA-600SSK - DIMENSIONS TOP AND SIDE Figure 1. DimensionsFigure 2. Dimensions DCA-600SSK - DIMENSIONS FRONT , REAR AND DOORSDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERDCA-600SSK - SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDCA-600SSK - RULES FOR SAFE OPERATION General SafetyDANGER - READTHIS MANUAL Electrical Safety DCA-600SSK - RULES FOR SAFE OPERATIONGenerator Grounding DANGER - ELECTROCUTION HAZARDSMaintenance Safety Battery SafetyDCA-600SSK- RULES FOR SAFE OPERATION DANGER - EXPLOSION HAZARDSDCA-600SSK - RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies DCA-600SSK - INSTALLATION Figure 3. Typical Generator Grounding ApplicationDCA-600SSK - INSTALLATION Outdoor InstallationCAUTION - EXHAUST HAZARD MountingTowing Safety Precautions DCA-600SSK -TOWING RULES FOR SAFE OPERATIONCAUTION -TOWING REGULATIONS Figure 4. Generator and TrailerExplanation of Chart DCA-600SSK - TRAILER-SAFETY GUIDELINESCAUTION - TRAILER INSPECTION DCA-600SSK -TRAILER-SPECIFICATIONS Table 3. Trailer SpecificationsMODEL FUEL CELLDCA-600SSK -TRAILER-SPECIFICATIONS Table 3. Specifications ContDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE MODELDCA-600SSK - OPERATION AND SAFETY DECALS Machine Safety DecalsDCA-600SSK - OPERATION AND SAFETY DECALS DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEDCA-600SSK - OPERATION AND SAFETY DECALS DCA-600SSK - OPERATION AND SAFETY DECALS DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEMicroprocessor Controlled Alarm System DCA-600SSK - GENERAL INFORMATIONDCA-600SSK FAMILIARIZATION Generator Engine Control PanelDCA-600SSK - MAJOR COMPONENTS Table 4. Generator Major ComponentsDESCRIPTION DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEDCA-600SSK - GENERATOR CONTROL PANEL Up to S/N S/N 3698617~ Figure 6. Generator Control PanelDCA-600SSK - GENERATOR CONTROL PANEL DCA-600SSK - ENGINE OPERATING PANEL Up to S/N S/N 3698617~ Figure 7. Engine Operating Panels8. 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 DCA-600SSK - OUTPUTTERMINAL OVERVIEW Output Terminal FamiliarizationThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal PanelAccess to UVWO Terminals DCA-600SSK - OUTPUT TERMINAL PANEL OVERVIEW120VAC GFCI Receptacles Figure 9. G.F.C.I. ReceptacleConnecting Loads Maximum Power Output KWDCA-600SSK - OUTPUT TERMINAL PANEL OVERVIEW Over Current RelaySingle Phase Load Three Phase LoadDCA-600SSK- LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSDCA-600SSK - GENERATOR OUTPUTS Table 9. Generator Ampere Ratings - 3ØTable 7. Generator Available Voltages Generator OutputVoltagesHow to Read the Output Terminal Gauge DCA-600SSK - GENERATOR OUTPUTS/GAUGE READINGMaximum Amps Figure 19. AC Ammeter Change-Over SwitchDCA-600SSK - OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output VoltagesDCA-600SSK - OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480V UVWO Terminal Output Voltages1Ø-480V UVWO Terminal Output Voltages 1Ø-277V UVWO Terminal Output VoltagesDCA-600SSK - PRE-SETUP Table 11. Recommended Motor OilCircuit Breakers Lubrication OilRefueling Procedure CAUTION -TRAILER FUELTANKWARNING - RESPIRATORY HAZARDS refuelingDCA-600SSK - PRE-SETUP CAUTION - REFUELINGTHE GENERATORFigure 35. Full Trailer Tank Figure 37. Full Fuel SystemDCA-600SSK- PRE-SETUP Cleaning the RadiatorAir Cleaner Table 12. Coolant CapacityBattery Battery Cable InstallationCAUTION - BATTERY SERVICING SAFETY WiringDCA-600SSK - GEN. START-UP PROCEDURE MANUAL BEFORE STARTINGCAUTION - 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 DCA-600SSK- GENERATOR START-UP PROCEDURE MANUAL Figure 54. Oil Pressure GaugeFigure 57. Main, Aux. and GFCI Circuit Breakers ON Figure 55. Coolant Temperature GaugeDCA-600SSK - GENERATOR START-UP PROCEDURE MANUAL 20. Set the battery ON/OFF switch Figure 60 to the “ON” positionBEFORE STARTING Generator and Control PanelDCA-600SSK - GENERATOR START-UP PROCEDURE AUTO MODE CAUTION - ENGINE SPEED SWITCHCAUTION - BACKUP GENERATOR USE WARNING - AUTO MODE MAINTENANCEDCA-600SSK - GENERATOR SHUT-DOWN PROCEDURE Emergency Shutdown ProcedureCAUTION - EMERGENCY STOP SWITCH Engine Shutdown Controller S/N 3698617~DCA-600SSK - MAINTENANCE INSPECTION / MAINTENANCEENGINE DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEService Daily Cleaning the Fuel StrainerGeneral Inspection Outer ElementFlushing Out Radiator and Changing Coolant Changing OilReplacing Fuel Filter DCA-600SSK - MAINTENANCECleaning Breather Element GreasingGenerator Storage Removal From Long Term StorageDCA-600SSK - MAINTENANCE NOTEapplied to the generators internal battery chargerFigure 75. Battery Charger/Jacket Water Heater Power Connections DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEDCA-600SSK -TRAILER BRAKES MAINTENANCE BrakesAir Brake System S-Cam BrakesDCA-600SSK -TRAILER MAINTENANCE Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD Tire Wear/InflationDCA-600SSK -TRAILER MAINTENANCE Lug Nut Torque RequirementsFigure 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 DCA-600SSK -TRAILER-WIRING DIAGRAM Figure 80. Trailer Wiring Diagram 7-PinFigure 81. Generator Wiring Diagram DCA-600SSK -GENERATORWIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - GENERATOR WIRING DIAGRAM MAIN BREAKER Figure 82. Main Circuit Breaker Wiring DiagramFigure 83. Engine Wiring Diagram DCA-600SSK - ENGINE WIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK - ENGINE WIRING DIAGRAM Figure 84. Engine Wiring DiagramContinuedFigure 85. Electronic Governor Controller DCA-600SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAMDCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGE DCA-600SSK -TROUBLESHOOTING ENGINE TABLE 20. ENGINE TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-600SSK -TROUBLESHOOTING ENGINE TABLE 20. ENGINE TROUBLESHOOTING CONTINUEDSYMPTOM POSSIBLE PROBLEMDCA-600SSK -TROUBLESHOOTING GENERATOR/ENGINE TABLE 21. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-600SSK -TROUBLESHOOTING MPEC TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPECSolution SymptonEXPLANATION OF CODE IN REMARKS COLUMN SAMPLE PARTS LISTQTY. Column NO. ColumnDCA-600SSK - SUGGESTED SPARE PARTS DCA-600SSK w/SA6D170AE-1 KOMATSU ENGINE1 to 3 Units DescriptionDCA-600SSK - GENERATOR ASSY GENERATOR ASSYPART NAME REMARKSDCA-600SSK - GENERATOR ASSY INCLUDE ITEMS WDCA-600SSK - GENERATOR ASSY PART NAME DCA-600SSK - GENERATOR ASSYREMARKS DCA-600SSK - CONTROL BOX ASSY CONTROL BOX ASSYDCA-600SSK - CONTROL BOX ASSY PART NAMEREMARKS REPLACESDCA-600SSK - CONTROL BOX ASSY CHANGE-OVER SWITCH, AMMETER DCA-600SSK - CONTROL BOX ASSYPART 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 DCA-600SSK - ENGINE & RADIATOR ASSY ENGINE & RADIATOR ASSYPART NAME DCA-600SSK - ENGINE & RADIATOR ASSYREMARKS DCA-600SSK - ENGINE & RADIATOR ASSY PART NAME DCA-600SSK - ENGINE & RADIATOR ASSYREMARKS DCA-600SSK - ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSYDCA-600SSK - ENGINE OPERATING PANEL ASSY PART NAMEREMARKS S/N 3698617 AND ABOVEDCA-600SSK - OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYDCA-600SSK - OUTPUTTERMINAL ASSY PART NAMEREMARKS SET BOARD, OUTPUT TERMINALDCA-600SSK - OUTPUTTERMINAL ASSY PART NAME DCA-600SSK - OUTPUTTERMINAL ASSYREMARKS DCA-600SSK - BATTERY ASSY BATTERY ASSYPART NAME DCA-600SSK - BATTERY ASSYREMARKS DCA-600SSK - MUFFLER ASSY MUFFLER ASSYPART NAME DCA-600SSK - MUFFLER ASSYREMARKS DCA-600SSK - FUELTANK ASSY FUEL TANK ASSYPART NAME DCA-600SSK - FUELTANK ASSYREMARKS DCA-600SSK - ENCLOSURE #1 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-600SSK - ENCLOSURE #1 ASSY DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEPART NAME REMARKSDCA-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-GRAYDCA-600SSK - ENCLOSURE #2 ASSY PART NAMEREMARKS ENCLOSURE #2 ASSYTHE 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 DCA-600SSK - ENCLOSURE #3 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 #3 ASSYREMARKS DCA-600SSK - RUBBER SEAL ASSY RUBBER SEAL ASSYDCA-600SSK - RUBBER SEAL ASSY PART NAMEDCA-600SSK - NAMEPLATE AND DECALS NAME PLATE AND DECALSCONTROL BOX GROUP ENGINE OPERATING PANEL GROUPDCA-600SSK - NAMEPLATE AND DECALS PART NAMEDCA-600SSK - NAMEPLATE AND DECALS DCA-600SSK - NAMEPLATE AND DECALS PART NAMEREMARKS OUTPUTTERMINAL GROUPTERMS AND CONDITIONS OF SALE - PARTS Effective October 1SPECIAL EXPEDITING SERVICE PAYMENT TERMSNOTE PAGE DCA-600SSK - OPERATION AND PARTS MANUAL STD- REV. #7 04/30/10 - PAGEContact mqpower@multiquip.com 18910 Wilmington AveCarson, CA Contact mq@multiquip.com