PARTS LIST NO. C4874303204
OPERATION AND PARTS MANUAL
MODEL DCA-600SSV
WHISPERWATTTM SERIES
Diesel engine exhaust and some of
PROPOSITION 65WARNING
PAGE 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 CONTENTS
COMPONENT DRAWINGS
64-67
When ordering parts, please supply
PARTS ORDERING PROCEDURES
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Table 1. Generator Specifications
DCA-600SSV - SPECIFICATIONS
Table 2. Engine Specifications
Dry Weight
TABLE 3. DIMENSIONS
DCA-600SSV - DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
HAZARD SYMBOLS
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
DANGER
WARNING - ROTATING PARTS
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEED CONDITIONS
DCA-600SSV - RULES FOR SAFE OPERATION
General Safety
DANGER - READTHIS MANUAL
DCA-600SSV - RULES FOR SAFE OPERATION
Electrical Safety
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
Battery Safety
Maintenance Safety
DCA-600SSV- RULES FOR SAFE OPERATION
DANGER - EXPLOSION HAZARDS
DCA-600SSV - RULES FOR SAFE OPERATION
Towing & Transporting Safety
Emergencies
Machine Safety Decals
DCA-600SSV - GENERATOR DECALS
Figure 2. Generator Decals
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Figure 2. Generator Decals
DCA-600SSV - GENERATOR DECALS
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
Figure 2. Generator Decals
DCA-600SSV - GENERATOR DECALS
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Figure 3. Generator Decals
DCA-600SSV - GENERATOR DECALS
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
Figure 4. Typical Generator Grounding Application
DCA-600SSV - INSTALLATION
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Outdoor Installation
DCA-600SSV - INSTALLATION
CAUTION - EXHAUST HAZARD
Mounting
Generator
DCA-600SSV - GENERAL INFORMATION
Engine Operating Panel
Generator Control Panel
Table 4. Generator Major Components
DCA-600SSV - MAJOR COMPONENTS
Figure 5. Major Components
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
1. Pilot Lamp - Indicates that the generator is working properly
DCA-600SSV - GENERATOR CONTROL PANEL
Figure 6. Generator Control Panel
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DCA-600SSV - GENERATOR CONTROL PANEL
When the circuit
lamp will be turned OFF
be turned ON
BATTERY SWITCH
DCA-600SSV - ENGINE OPERATING PANEL
Figure 7. Engine Operating Panels
PAGE 24 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
C. Low Fuel Level Lamp - When this lamp is
DCA-600SSV - ENGINE OPERATING PANEL
Output Terminal Familiarization
DCA-600SSV - OUTPUTTERMINAL FAMILIARIZATION
The “Output Terminal Panel ” Figure 8 is provided with the following
Output Terminal Panel
120VAC GFCI Receptacles
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
Figure 11. Voltage Regulator Control Knob
Figure 9 G.F.C.I. Receptacle
Maximum Power Output KW
Connecting Loads
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
Three Phase Load
Single Phase Load
DCA-600SSV- LOAD APPLICATION
DANGER - ELECTRICAL SYSTEM HAZARDS
Table 7. Generator Available Voltages
DCA-600SSV - GENERATOR OUTPUTS
Generator OutputVoltages
Voltage Change-Over Board
AC Ammeter Gauge Reading
DCA-600SSV - GENERATOR OUTPUTS/GAUGE READING
ACVoltmeter Gauge Reading
Figure 15. Voltage Change-Over Board 240V/3Ø Configuration
UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-240V UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
3Ø-480V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
1Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
Table 9. Recommended Motor Oil
DCA-600SSV - SETUP
Circuit Breakers
Lubrication Oil
WARNING - RESPIRATORY HAZARDS
Refueling Procedure
CAUTION -TRAILER FUELTANK
refueling
CAUTION - REFUELINGTHE GENERATOR
DCA-600SSV - SETUP
Figure 34. Full Trailer Tank
Figure 36. Full Fuel System
Cleaning the Radiator
DCA-600SSV- SETUP
Air Cleaner
Table 10. Coolant Capacity
Battery Cable Installation
Battery
CAUTION - BATTERY SERVICING SAFETY
Wiring
BEFORE STARTING
DCA-600SSV - GEN. START-UP PROCEDURE MANUAL
CAUTION - LETHAL EXHAUST HAZARD
Generator and Control Panel
7. Set the battery ON/OFF switch Figure 45 to the “ON” position
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
Figure 58. Main Circuit Breaker ON Switch
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
Figure 56. Coolant Temperature Gauge
Figure 54. Ammeter No Load
CAUTION - BACKUP GENERATOR USE
DCA-600SSV - GENERATOR START-UP PROCEDURE AUTO MODE
WARNING - AUTO MODE MAINTENANCE
CAUTION - ENGINE SPEED SWITCH
Normal Shutdown Procedure
DCA-600SSV - GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
PUSH TO STOP
TABLE 14. INSPECTION/MAINTENANCE
DCA-600SSV - MAINTENANCE
Air Cleaner with Dust Indicator
General Inspection
Cleaning Inside the Fuel Tank
Service Daily
Cleaning the Fuel Strainer
Fuel Addition
Air Removal
Radiator Cleaning
Check Oil Level
Replacing Oil Filter
To ensure adequate starting
DCA-600SSV - MAINTENANCE
Electric Brakes
DCA-600SSV -TRAILER BRAKES MAINTENANCE
Magnets For All Electric Brakes
Brake Controller
Tires/Wheels/Lug Nuts
DCA-600SSV -TRAILER MAINTENANCE
CAUTION - EYESIGHT HAZARD
Tire Wear/Inflation
Lug Nut Torque Requirements
DCA-600SSV -TRAILER MAINTENANCE
Figure 71. Wheel Lug Nuts Tightening Sequence
PAGE 50 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
Figure 72. Trailer Wiring Diagram 5-Pin
DCA-600SSV -TRAILER-WIRING DIAGRAM
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
Figure 73. Trailer Wiring Diagram 7-Pin
DCA-600SSV -TRAILER-WIRING DIAGRAM
PAGE 52 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
Figure 74. Generator Wiring Diagram
DCA-600SSV -GENERATORWIRING DIAGRAM
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
Figure 75. Main Circuit Breaker Wiring Diagram
DCA-600SSV - GENERATOR WIRING DIAGRAM MAIN BREAKER
PAGE 54 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
Figure 76. Engine Wiring Diagram
DCA-600SSV - ENGINEWIRING DIAGRAM
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
TABLE 18. ENGINE TROUBLESHOOTING
DCA-600SSV -TROUBLESHOOTING ENGINE
Engine does not start
Starter does not run
TABLE 18. ENGINE TROUBLESHOOTING CONTINUED
DCA-600SSV -TROUBLESHOOTING ENGINE
Engine revolution is not
smooth
TABLE 19. GENERATOR TROUBLESHOOTING
DCA-600SSV -TROUBLESHOOTING GENERATOR
SYMPTOM
POSSIBLE PROBLEM
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
DCA-600SSV -TROUBLESHOOTING ENGINE CONTROLLER
Solution
Sympton
Example Error Code
DCA-600SSV-TROUBLESHOOTING DIAGNOSTIC LAMP
When the MPEC Control
Method of Operation
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
NOTE PAGE
NO. Column
DCA-600SSV- EXPLANATION OF CODE IN REMARKS COLUMN
PART NO. Column
QTY. Column
DCA-600SSV w/SA6D170AE-1VOLVO ENGINE
DCA-600SSV - SUGGESTED SPARE PARTS
1 to 3 Units
Description
GENERATOR ASSY
DCA-600SSV - GENERATOR ASSY
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PART NAME
DCA-600SSV - GENERATOR ASSY
QTY. REMARKS
PAGE 66 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - GENERATOR ASSY. CONT
PART NAME
DCA-600SSV - GENERATOR ASSY. CONT
QTY. REMARKS
CONTROL BOX ASSY
DCA-600SSV - CONTROL BOX ASSY
PAGE 68 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - CONTROL BOX ASSY
RHEOSTAT HIGH IDLE SPEED REGULATOR
PAGE 70 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - CONTROL BOX ASSY. CONT
CHANGE-OVER SWITCH, AMMETER
CIRCUIT BREAKER RESET SWITCH
CHANGE-OVER SWITCH, VOLMETER
DCA-600SSV - CONTROL BOX ASSY. CONT
PAGE 72 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - CONTROL BOX ASSY. CONT
PART NAME
DCA-600SSV - CONTROL BOX ASSY. CONT
QTY. REMARKS
ENGINE AND RADIATOR ASSY
DCA-600SSV - ENGINE AND RADIATOR ASSY
PAGE 74 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - ENGINE AND RADIATOR ASSY
QTY. REMARKS
CARTRIDGE, OIL FILTER, BY-PASS
PAGE 76 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENGINE AND RADIATOR ASSY. CONT
PART NAME
DCA-600SSV - ENGINE AND RADIATOR ASSY. CONT
QTY. REMARKS
ENGINE OPERATING PANEL ASSY
DCA-600SSV - ENGINE OPERATING PANEL ASSY
PAGE 78 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
WATER TEMPERATURE GAUGE
SET PLATE, BATTERY SWITCH
CHANGE-OVER SWITCH, SPEED
DCA-600SSV - ENGINE OPERATING PANEL ASSY
OUTPUT TERMINAL ASSY
DCA-600SSV - OUTPUTTERMINAL ASSY
PAGE 80 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - OUTPUTTERMINAL ASSY
SET BOARD, OUTPUT TERMINAL
QTY. REMARKS
PAGE 82 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
PART NAME
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
BRACKET, CIRCUIT BREAKER
BATTERY ASSY
DCA-600SSV - BATTERY ASSY
PAGE 84 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - BATTERY ASSY
MUFFLER ASSY
DCA-600SSV - MUFFLER ASSY
PAGE 86 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - MUFFLER ASSY
FUEL TANK ASSY
DCA-600SSV - FUELTANK ASSY
PAGE 88 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - FUELTANK ASSY
ENCLOSURE #1 ASSY
DCA-600SSV - ENCLOSURE #1 ASSY
PAGE 90 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - ENCLOSURE #1 ASSY
QTY. REMARKS
COVER, FRONT FRAME
PAGE 92 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
PART NAME
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
QTY. REMARKS
ENCLOSURE #2 ASSY
DCA-600SSV - ENCLOSURE #2 ASSY
PAGE 94 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - ENCLOSURE #2 ASSY
QTY. REMARKS
ENCLOSURE #2 ASSY
PAGE 96 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #2 ASSY. CONT
PART NAME
DCA-600SSV - ENCLOSURE #2 ASSY. CONT
ENCLOSURE #3 ASSY
DCA-600SSV - ENCLOSURE #3 ASSY
PAGE 98 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - ENCLOSURE #3 ASSY
QTY. REMARKS
RUBBER SEAL ASSY
DCA-600SSV - RUBBER SEAL ASSY
PAGE 100 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - RUBBER SEAL ASSY
NAME PLATE AND DECALS
DCA-600SSV - NAMEPLATE AND DECALS
PAGE 102 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - NAMEPLATE AND DECALS
C3551002303
PAGE 104 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - NAMEPLATE AND DECALS CONT
PART NAME
DCA-600SSV - NAMEPLATE AND DECALS CONT
Effective October 1
TERMS AND CONDITIONS OF SALE - PARTS
11. Credit issued will be applied to future purchasesonly
SPECIAL EXPEDITING SERVICE
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
NOTE PAGE
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERES HOW TO GET HELP
MQPOWER
OPERATION AND PARTS MANUAL