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Multiquip operation manual Operation And Parts Manual, MODEL DCA-600SSV, Whisperwatttm Series

Models: DCA-600SSV

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OPERATION AND PARTS MANUAL

WHISPERWATTTM SERIES

MODEL DCA-600SSV

60 Hz GENERATOR

PARTS LIST NO. C4874303204

Revision #0 (07/13/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALLTIMES.

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Multiquip operation manual Operation And Parts Manual, MODEL DCA-600SSV, Whisperwatttm Series, Hz GENERATOR

Contents

PARTS LIST NO. C4874303204 OPERATION AND PARTS MANUALMODEL DCA-600SSV WHISPERWATTTM SERIESDiesel engine exhaust and some of PROPOSITION 65WARNINGPAGE 2 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 REPORTING SAFETY DEFECTS MQ Power DCA-600SSV 60 Hz AC Generator TABLE OF CONTENTSCOMPONENT DRAWINGS 64-67When ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Choose from three easy optionsTable 1. Generator Specifications DCA-600SSV - SPECIFICATIONSTable 2. Engine Specifications Dry WeightTABLE 3. DIMENSIONS DCA-600SSV - DIMENSIONS TOP, SIDE AND FRONTFigure 1. Dimensions DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGEHAZARD SYMBOLS DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERWARNING - ROTATING PARTS DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSDCA-600SSV - RULES FOR SAFE OPERATION General SafetyDANGER - READTHIS MANUAL DCA-600SSV - RULES FOR SAFE OPERATION Electrical SafetyGenerator Grounding DANGER - ELECTROCUTION HAZARDSBattery Safety Maintenance SafetyDCA-600SSV- RULES FOR SAFE OPERATION DANGER - EXPLOSION HAZARDSDCA-600SSV - RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies Machine Safety Decals DCA-600SSV - GENERATOR DECALSFigure 2. Generator Decals PAGE 14 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09Figure 2. Generator Decals DCA-600SSV - GENERATOR DECALSDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE Figure 2. Generator Decals DCA-600SSV - GENERATOR DECALSPAGE 16 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 Figure 3. Generator Decals DCA-600SSV - GENERATOR DECALSDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE Figure 4. Typical Generator Grounding Application DCA-600SSV - INSTALLATIONPAGE 18 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 Outdoor Installation DCA-600SSV - INSTALLATIONCAUTION - EXHAUST HAZARD MountingGenerator DCA-600SSV - GENERAL INFORMATIONEngine Operating Panel Generator Control PanelTable 4. Generator Major Components DCA-600SSV - MAJOR COMPONENTSFigure 5. Major Components DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE1. Pilot Lamp - Indicates that the generator is working properly DCA-600SSV - GENERATOR CONTROL PANELFigure 6. Generator Control Panel PAGE 22 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09DCA-600SSV - GENERATOR CONTROL PANEL When the circuitlamp will be turned OFF be turned ONBATTERY SWITCH DCA-600SSV - ENGINE OPERATING PANELFigure 7. Engine Operating Panels PAGE 24 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09C. Low Fuel Level Lamp - When this lamp is DCA-600SSV - ENGINE OPERATING PANELOutput Terminal Familiarization DCA-600SSV - OUTPUTTERMINAL FAMILIARIZATIONThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal Panel120VAC GFCI Receptacles DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATIONFigure 11. Voltage Regulator Control Knob Figure 9 G.F.C.I. ReceptacleMaximum Power Output KW Connecting LoadsDCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current RelayThree Phase Load Single Phase LoadDCA-600SSV- LOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSTable 7. Generator Available Voltages DCA-600SSV - GENERATOR OUTPUTSGenerator OutputVoltages Voltage Change-Over BoardAC Ammeter Gauge Reading DCA-600SSV - GENERATOR OUTPUTS/GAUGE READINGACVoltmeter Gauge Reading Figure 15. Voltage Change-Over Board 240V/3Ø ConfigurationUVWO Terminal Output Voltages DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages3Ø-480V UVWO Terminal Output Voltages DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS1Ø-480V UVWO Terminal Output Voltages 1Ø-277V UVWO Terminal Output VoltagesTable 9. Recommended Motor Oil DCA-600SSV - SETUPCircuit Breakers Lubrication OilWARNING - RESPIRATORY HAZARDS Refueling ProcedureCAUTION -TRAILER FUELTANK refuelingCAUTION - REFUELINGTHE GENERATOR DCA-600SSV - SETUPFigure 34. Full Trailer Tank Figure 36. Full Fuel SystemCleaning the Radiator DCA-600SSV- SETUPAir Cleaner Table 10. Coolant CapacityBattery Cable Installation BatteryCAUTION - BATTERY SERVICING SAFETY WiringBEFORE STARTING DCA-600SSV - GEN. START-UP PROCEDURE MANUALCAUTION - LETHAL EXHAUST HAZARD Generator and Control Panel7. Set the battery ON/OFF switch Figure 45 to the “ON” position DCA-600SSV- GENERATOR START-UP PROCEDURE MANUALFigure 58. Main Circuit Breaker ON Switch DCA-600SSV- GENERATOR START-UP PROCEDURE MANUALFigure 56. Coolant Temperature Gauge Figure 54. Ammeter No LoadCAUTION - BACKUP GENERATOR USE DCA-600SSV - GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE CAUTION - ENGINE SPEED SWITCHNormal Shutdown Procedure DCA-600SSV - GENERATOR SHUT-DOWN PROCEDUREEmergency Shutdown Procedure PUSH TO STOPTABLE 14. INSPECTION/MAINTENANCE DCA-600SSV - MAINTENANCEAir Cleaner with Dust Indicator General InspectionCleaning Inside the Fuel Tank Service DailyCleaning the Fuel Strainer Fuel AdditionAir Removal Radiator CleaningCheck Oil Level Replacing Oil FilterTo ensure adequate starting DCA-600SSV - MAINTENANCEElectric Brakes DCA-600SSV -TRAILER BRAKES MAINTENANCEMagnets For All Electric Brakes Brake ControllerTires/Wheels/Lug Nuts DCA-600SSV -TRAILER MAINTENANCECAUTION - EYESIGHT HAZARD Tire Wear/InflationLug Nut Torque Requirements DCA-600SSV -TRAILER MAINTENANCEFigure 71. Wheel Lug Nuts Tightening Sequence PAGE 50 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09Figure 72. Trailer Wiring Diagram 5-Pin DCA-600SSV -TRAILER-WIRING DIAGRAMDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE Figure 73. Trailer Wiring Diagram 7-Pin DCA-600SSV -TRAILER-WIRING DIAGRAMPAGE 52 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 Figure 74. Generator Wiring Diagram DCA-600SSV -GENERATORWIRING DIAGRAMDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE Figure 75. Main Circuit Breaker Wiring Diagram DCA-600SSV - GENERATOR WIRING DIAGRAM MAIN BREAKERPAGE 54 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 Figure 76. Engine Wiring Diagram DCA-600SSV - ENGINEWIRING DIAGRAMDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE TABLE 18. ENGINE TROUBLESHOOTING DCA-600SSV -TROUBLESHOOTING ENGINEEngine does not start Starter does not runTABLE 18. ENGINE TROUBLESHOOTING CONTINUED DCA-600SSV -TROUBLESHOOTING ENGINEEngine revolution is not smoothTABLE 19. GENERATOR TROUBLESHOOTING DCA-600SSV -TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMTABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC DCA-600SSV -TROUBLESHOOTING ENGINE CONTROLLERSolution SymptonExample Error Code DCA-600SSV-TROUBLESHOOTING DIAGNOSTIC LAMPWhen the MPEC Control Method of OperationDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE NOTE PAGENO. Column DCA-600SSV- EXPLANATION OF CODE IN REMARKS COLUMNPART NO. Column QTY. ColumnDCA-600SSV w/SA6D170AE-1VOLVO ENGINE DCA-600SSV - SUGGESTED SPARE PARTS1 to 3 Units DescriptionGENERATOR ASSY DCA-600SSV - GENERATOR ASSYPAGE 64 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - GENERATOR ASSYQTY. REMARKS PAGE 66 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - GENERATOR ASSY. CONTPART NAME DCA-600SSV - GENERATOR ASSY. CONTQTY. REMARKS CONTROL BOX ASSY DCA-600SSV - CONTROL BOX ASSYPAGE 68 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - CONTROL BOX ASSYRHEOSTAT HIGH IDLE SPEED REGULATOR PAGE 70 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - CONTROL BOX ASSY. CONTCHANGE-OVER SWITCH, AMMETER CIRCUIT BREAKER RESET SWITCHCHANGE-OVER SWITCH, VOLMETER DCA-600SSV - CONTROL BOX ASSY. CONTPAGE 72 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - CONTROL BOX ASSY. CONTPART NAME DCA-600SSV - CONTROL BOX ASSY. CONTQTY. REMARKS ENGINE AND RADIATOR ASSY DCA-600SSV - ENGINE AND RADIATOR ASSYPAGE 74 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - ENGINE AND RADIATOR ASSYQTY. REMARKS CARTRIDGE, OIL FILTER, BY-PASSPAGE 76 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - ENGINE AND RADIATOR ASSY. CONTPART NAME DCA-600SSV - ENGINE AND RADIATOR ASSY. CONTQTY. REMARKS ENGINE OPERATING PANEL ASSY DCA-600SSV - ENGINE OPERATING PANEL ASSYPAGE 78 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 WATER TEMPERATURE GAUGE SET PLATE, BATTERY SWITCHCHANGE-OVER SWITCH, SPEED DCA-600SSV - ENGINE OPERATING PANEL ASSYOUTPUT TERMINAL ASSY DCA-600SSV - OUTPUTTERMINAL ASSYPAGE 80 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - OUTPUTTERMINAL ASSYSET BOARD, OUTPUT TERMINAL QTY. REMARKSPAGE 82 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - OUTPUTTERMINAL ASSY. CONTPART NAME DCA-600SSV - OUTPUTTERMINAL ASSY. CONTBRACKET, CIRCUIT BREAKER BATTERY ASSY DCA-600SSV - BATTERY ASSYPAGE 84 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - BATTERY ASSYMUFFLER ASSY DCA-600SSV - MUFFLER ASSYPAGE 86 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - MUFFLER ASSYFUEL TANK ASSY DCA-600SSV - FUELTANK ASSYPAGE 88 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - FUELTANK ASSYENCLOSURE #1 ASSY DCA-600SSV - ENCLOSURE #1 ASSYPAGE 90 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - ENCLOSURE #1 ASSYQTY. REMARKS COVER, FRONT FRAMEPAGE 92 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - ENCLOSURE #1 ASSY. CONTPART NAME DCA-600SSV - ENCLOSURE #1 ASSY. CONTQTY. REMARKS ENCLOSURE #2 ASSY DCA-600SSV - ENCLOSURE #2 ASSYPAGE 94 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - ENCLOSURE #2 ASSYQTY. REMARKS ENCLOSURE #2 ASSYPAGE 96 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - ENCLOSURE #2 ASSY. CONTPART NAME DCA-600SSV - ENCLOSURE #2 ASSY. CONTENCLOSURE #3 ASSY DCA-600SSV - ENCLOSURE #3 ASSYPAGE 98 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - ENCLOSURE #3 ASSYQTY. REMARKS RUBBER SEAL ASSY DCA-600SSV - RUBBER SEAL ASSYPAGE 100 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - RUBBER SEAL ASSYNAME PLATE AND DECALS DCA-600SSV - NAMEPLATE AND DECALSPAGE 102 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 PART NAME DCA-600SSV - NAMEPLATE AND DECALSC3551002303 PAGE 104 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 DCA-600SSV - NAMEPLATE AND DECALS CONTPART NAME DCA-600SSV - NAMEPLATE AND DECALS CONTEffective October 1 TERMS AND CONDITIONS OF SALE - PARTS11. Credit issued will be applied to future purchasesonly SPECIAL EXPEDITING SERVICEDCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE NOTE PAGEPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING HERES HOW TO GET HELPMQPOWER OPERATION AND PARTS MANUAL