MODEL DCA-600SSV
OPERATION AND PARTS MANUAL
PARTS LIST NO. C4874303204
WHISPERWATTTM SERIES
PAGE 2 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PROPOSITION 65WARNING
Diesel engine exhaust and some of
REPORTING SAFETY DEFECTS
COMPONENT DRAWINGS
TABLE OF CONTENTS
MQ Power DCA-600SSV 60 Hz AC Generator
64-67
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PARTS ORDERING PROCEDURES
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Choose from three easy options
Table 2. Engine Specifications
DCA-600SSV - SPECIFICATIONS
Table 1. Generator Specifications
Dry Weight
Figure 1. Dimensions
DCA-600SSV - DIMENSIONS TOP, SIDE AND FRONT
TABLE 3. DIMENSIONS
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
SAFETY MESSAGE ALERT SYMBOLS
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
DANGER
CAUTION - ACCIDENTAL STARTING
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - OVER-SPEED CONDITIONS
DANGER - READTHIS MANUAL
General Safety
DCA-600SSV - RULES FOR SAFE OPERATION
Generator Grounding
Electrical Safety
DCA-600SSV - RULES FOR SAFE OPERATION
DANGER - ELECTROCUTION HAZARDS
DCA-600SSV- RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
DANGER - EXPLOSION HAZARDS
Emergencies
Towing & Transporting Safety
DCA-600SSV - RULES FOR SAFE OPERATION
Figure 2. Generator Decals
DCA-600SSV - GENERATOR DECALS
Machine Safety Decals
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DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - GENERATOR DECALS
Figure 2. Generator Decals
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DCA-600SSV - GENERATOR DECALS
Figure 2. Generator Decals
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - GENERATOR DECALS
Figure 3. Generator Decals
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DCA-600SSV - INSTALLATION
Figure 4. Typical Generator Grounding Application
CAUTION - EXHAUST HAZARD
DCA-600SSV - INSTALLATION
Outdoor Installation
Mounting
Engine Operating Panel
DCA-600SSV - GENERAL INFORMATION
Generator
Generator Control Panel
Figure 5. Major Components
DCA-600SSV - MAJOR COMPONENTS
Table 4. Generator Major Components
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
Figure 6. Generator Control Panel
DCA-600SSV - GENERATOR CONTROL PANEL
1. Pilot Lamp - Indicates that the generator is working properly
PAGE 22 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
lamp will be turned OFF
When the circuit
DCA-600SSV - GENERATOR CONTROL PANEL
be turned ON
Figure 7. Engine Operating Panels
DCA-600SSV - ENGINE OPERATING PANEL
BATTERY SWITCH
PAGE 24 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENGINE OPERATING PANEL
C. Low Fuel Level Lamp - When this lamp is
The “Output Terminal Panel ” Figure 8 is provided with the following
DCA-600SSV - OUTPUTTERMINAL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
Figure 11. Voltage Regulator Control Knob
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Figure 9 G.F.C.I. Receptacle
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Maximum Power Output KW
Over Current Relay
DCA-600SSV- LOAD APPLICATION
Single Phase Load
Three Phase Load
DANGER - ELECTRICAL SYSTEM HAZARDS
Generator OutputVoltages
DCA-600SSV - GENERATOR OUTPUTS
Table 7. Generator Available Voltages
Voltage Change-Over Board
ACVoltmeter Gauge Reading
DCA-600SSV - GENERATOR OUTPUTS/GAUGE READING
AC Ammeter Gauge Reading
Figure 15. Voltage Change-Over Board 240V/3Ø Configuration
3Ø-240V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
Circuit Breakers
DCA-600SSV - SETUP
Table 9. Recommended Motor Oil
Lubrication Oil
CAUTION -TRAILER FUELTANK
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
refueling
Figure 34. Full Trailer Tank
DCA-600SSV - SETUP
CAUTION - REFUELINGTHE GENERATOR
Figure 36. Full Fuel System
Air Cleaner
DCA-600SSV- SETUP
Cleaning the Radiator
Table 10. Coolant Capacity
CAUTION - BATTERY SERVICING SAFETY
Battery
Battery Cable Installation
Wiring
CAUTION - LETHAL EXHAUST HAZARD
DCA-600SSV - GEN. START-UP PROCEDURE MANUAL
BEFORE STARTING
Generator and Control Panel
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
7. Set the battery ON/OFF switch Figure 45 to the “ON” position
Figure 56. Coolant Temperature Gauge
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
Figure 58. Main Circuit Breaker ON Switch
Figure 54. Ammeter No Load
WARNING - AUTO MODE MAINTENANCE
DCA-600SSV - GENERATOR START-UP PROCEDURE AUTO MODE
CAUTION - BACKUP GENERATOR USE
CAUTION - ENGINE SPEED SWITCH
Emergency Shutdown Procedure
DCA-600SSV - GENERATOR SHUT-DOWN PROCEDURE
Normal Shutdown Procedure
PUSH TO STOP
Air Cleaner with Dust Indicator
DCA-600SSV - MAINTENANCE
TABLE 14. INSPECTION/MAINTENANCE
General Inspection
Cleaning the Fuel Strainer
Service Daily
Cleaning Inside the Fuel Tank
Fuel Addition
Check Oil Level
Radiator Cleaning
Air Removal
Replacing Oil Filter
DCA-600SSV - MAINTENANCE
To ensure adequate starting
Magnets For All Electric Brakes
DCA-600SSV -TRAILER BRAKES MAINTENANCE
Electric Brakes
Brake Controller
CAUTION - EYESIGHT HAZARD
DCA-600SSV -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Figure 71. Wheel Lug Nuts Tightening Sequence
DCA-600SSV -TRAILER MAINTENANCE
Lug Nut Torque Requirements
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DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV -TRAILER-WIRING DIAGRAM
Figure 72. Trailer Wiring Diagram 5-Pin
PAGE 52 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV -TRAILER-WIRING DIAGRAM
Figure 73. Trailer Wiring Diagram 7-Pin
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV -GENERATORWIRING DIAGRAM
Figure 74. Generator Wiring Diagram
PAGE 54 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - GENERATOR WIRING DIAGRAM MAIN BREAKER
Figure 75. Main Circuit Breaker Wiring Diagram
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - ENGINEWIRING DIAGRAM
Figure 76. Engine Wiring Diagram
Engine does not start
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING
Starter does not run
Engine revolution is not
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING CONTINUED
smooth
SYMPTOM
DCA-600SSV -TROUBLESHOOTING GENERATOR
TABLE 19. GENERATOR TROUBLESHOOTING
POSSIBLE PROBLEM
Solution
DCA-600SSV -TROUBLESHOOTING ENGINE CONTROLLER
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Sympton
When the MPEC Control
DCA-600SSV-TROUBLESHOOTING DIAGNOSTIC LAMP
Example Error Code
Method of Operation
NOTE PAGE
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
PART NO. Column
DCA-600SSV- EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
QTY. Column
1 to 3 Units
DCA-600SSV - SUGGESTED SPARE PARTS
DCA-600SSV w/SA6D170AE-1VOLVO ENGINE
Description
PAGE 64 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - GENERATOR ASSY
GENERATOR ASSY
QTY. REMARKS
DCA-600SSV - GENERATOR ASSY
PART NAME
DCA-600SSV - GENERATOR ASSY. CONT
PAGE 66 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
QTY. REMARKS
DCA-600SSV - GENERATOR ASSY. CONT
PART NAME
PAGE 68 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - CONTROL BOX ASSY
CONTROL BOX ASSY
RHEOSTAT HIGH IDLE SPEED REGULATOR
DCA-600SSV - CONTROL BOX ASSY
PART NAME
DCA-600SSV - CONTROL BOX ASSY. CONT
PAGE 70 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
CHANGE-OVER SWITCH, VOLMETER
CIRCUIT BREAKER RESET SWITCH
CHANGE-OVER SWITCH, AMMETER
DCA-600SSV - CONTROL BOX ASSY. CONT
DCA-600SSV - CONTROL BOX ASSY. CONT
PAGE 72 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
QTY. REMARKS
DCA-600SSV - CONTROL BOX ASSY. CONT
PART NAME
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DCA-600SSV - ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
QTY. REMARKS
DCA-600SSV - ENGINE AND RADIATOR ASSY
PART NAME
CARTRIDGE, OIL FILTER, BY-PASS
DCA-600SSV - ENGINE AND RADIATOR ASSY. CONT
PAGE 76 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
QTY. REMARKS
DCA-600SSV - ENGINE AND RADIATOR ASSY. CONT
PART NAME
PAGE 78 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
CHANGE-OVER SWITCH, SPEED
SET PLATE, BATTERY SWITCH
WATER TEMPERATURE GAUGE
DCA-600SSV - ENGINE OPERATING PANEL ASSY
PAGE 80 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
SET BOARD, OUTPUT TERMINAL
DCA-600SSV - OUTPUTTERMINAL ASSY
PART NAME
QTY. REMARKS
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
PAGE 82 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
BRACKET, CIRCUIT BREAKER
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
PART NAME
PAGE 84 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - BATTERY ASSY
BATTERY ASSY
DCA-600SSV - BATTERY ASSY
PART NAME
PAGE 86 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - MUFFLER ASSY
MUFFLER ASSY
DCA-600SSV - MUFFLER ASSY
PART NAME
PAGE 88 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - FUELTANK ASSY
FUEL TANK ASSY
DCA-600SSV - FUELTANK ASSY
PART NAME
PAGE 90 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #1 ASSY
ENCLOSURE #1 ASSY
QTY. REMARKS
DCA-600SSV - ENCLOSURE #1 ASSY
PART NAME
COVER, FRONT FRAME
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
PAGE 92 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
QTY. REMARKS
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
PART NAME
PAGE 94 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #2 ASSY
ENCLOSURE #2 ASSY
QTY. REMARKS
DCA-600SSV - ENCLOSURE #2 ASSY
PART NAME
ENCLOSURE #2 ASSY
DCA-600SSV - ENCLOSURE #2 ASSY. CONT
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DCA-600SSV - ENCLOSURE #2 ASSY. CONT
PART NAME
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DCA-600SSV - ENCLOSURE #3 ASSY
ENCLOSURE #3 ASSY
QTY. REMARKS
DCA-600SSV - ENCLOSURE #3 ASSY
PART NAME
PAGE 100 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - RUBBER SEAL ASSY
RUBBER SEAL ASSY
DCA-600SSV - RUBBER SEAL ASSY
PART NAME
PAGE 102 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - NAMEPLATE AND DECALS
NAME PLATE AND DECALS
C3551002303
DCA-600SSV - NAMEPLATE AND DECALS
PART NAME
DCA-600SSV - NAMEPLATE AND DECALS CONT
PAGE 104 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - NAMEPLATE AND DECALS CONT
PART NAME
11. Credit issued will be applied to future purchasesonly
TERMS AND CONDITIONS OF SALE - PARTS
Effective October 1
SPECIAL EXPEDITING SERVICE
NOTE PAGE
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
MQPOWER
HERES HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
OPERATION AND PARTS MANUAL