OPERATION AND PARTS MANUAL
PARTS LIST NO. C4874303204
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
TABLE OF CONTENTS
MQ Power DCA-600SSV 60 Hz AC Generator
COMPONENT DRAWINGS
64-67
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Ordering parts has never been easier
Choose from three easy options
DCA-600SSV - SPECIFICATIONS
Table 1. Generator Specifications
Table 2. Engine Specifications
Dry Weight
DCA-600SSV - DIMENSIONS TOP, SIDE AND FRONT
TABLE 3. DIMENSIONS
Figure 1. Dimensions
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
DANGER
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEED CONDITIONS
DCA-600SSV - RULES FOR SAFE OPERATION
General Safety
DANGER - READTHIS MANUAL
Electrical Safety
DCA-600SSV - RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
Maintenance Safety
Battery Safety
DCA-600SSV- RULES FOR SAFE OPERATION
DANGER - EXPLOSION HAZARDS
DCA-600SSV - RULES FOR SAFE OPERATION
Towing & Transporting Safety
Emergencies
DCA-600SSV - GENERATOR DECALS
Machine Safety 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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DCA-600SSV - INSTALLATION
Outdoor Installation
CAUTION - EXHAUST HAZARD
Mounting
DCA-600SSV - GENERAL INFORMATION
Generator
Engine Operating Panel
Generator Control Panel
DCA-600SSV - MAJOR COMPONENTS
Table 4. Generator Major Components
Figure 5. Major Components
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - GENERATOR CONTROL PANEL
1. Pilot Lamp - Indicates that the generator is working properly
Figure 6. Generator Control Panel
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When the circuit
DCA-600SSV - GENERATOR CONTROL PANEL
lamp will be turned OFF
be turned ON
DCA-600SSV - ENGINE OPERATING PANEL
BATTERY SWITCH
Figure 7. Engine Operating Panels
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DCA-600SSV - ENGINE OPERATING PANEL
C. Low Fuel Level Lamp - When this lamp is
DCA-600SSV - OUTPUTTERMINAL FAMILIARIZATION
Output Terminal Familiarization
The “Output Terminal Panel ” Figure 8 is provided with the following
Output Terminal Panel
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Figure 11. Voltage Regulator Control Knob
Figure 9 G.F.C.I. Receptacle
Connecting Loads
Maximum Power Output KW
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
Over Current Relay
Single Phase Load
Three Phase Load
DCA-600SSV- LOAD APPLICATION
DANGER - ELECTRICAL SYSTEM HAZARDS
DCA-600SSV - GENERATOR OUTPUTS
Table 7. Generator Available Voltages
Generator OutputVoltages
Voltage Change-Over Board
DCA-600SSV - GENERATOR OUTPUTS/GAUGE READING
AC Ammeter Gauge Reading
ACVoltmeter Gauge Reading
Figure 15. Voltage Change-Over Board 240V/3Ø Configuration
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240V UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
DCA-600SSV - SETUP
Table 9. Recommended Motor Oil
Circuit Breakers
Lubrication Oil
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
CAUTION -TRAILER FUELTANK
refueling
DCA-600SSV - SETUP
CAUTION - REFUELINGTHE GENERATOR
Figure 34. Full Trailer Tank
Figure 36. Full Fuel System
DCA-600SSV- SETUP
Cleaning the Radiator
Air Cleaner
Table 10. Coolant Capacity
Battery
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
Wiring
DCA-600SSV - GEN. START-UP PROCEDURE MANUAL
BEFORE STARTING
CAUTION - LETHAL EXHAUST HAZARD
Generator and Control Panel
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
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
Figure 56. Coolant Temperature Gauge
Figure 54. Ammeter No Load
DCA-600SSV - GENERATOR START-UP PROCEDURE AUTO MODE
CAUTION - BACKUP GENERATOR USE
WARNING - AUTO MODE MAINTENANCE
CAUTION - ENGINE SPEED SWITCH
DCA-600SSV - GENERATOR SHUT-DOWN PROCEDURE
Normal Shutdown Procedure
Emergency Shutdown Procedure
PUSH TO STOP
DCA-600SSV - MAINTENANCE
TABLE 14. INSPECTION/MAINTENANCE
Air Cleaner with Dust Indicator
General Inspection
Service Daily
Cleaning Inside the Fuel Tank
Cleaning the Fuel Strainer
Fuel Addition
Radiator Cleaning
Air Removal
Check Oil Level
Replacing Oil Filter
DCA-600SSV - MAINTENANCE
To ensure adequate starting
DCA-600SSV -TRAILER BRAKES MAINTENANCE
Electric Brakes
Magnets For All Electric Brakes
Brake Controller
DCA-600SSV -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
Tire Wear/Inflation
DCA-600SSV -TRAILER MAINTENANCE
Lug Nut Torque Requirements
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
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING
Engine does not start
Starter does not run
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING CONTINUED
Engine revolution is not
smooth
DCA-600SSV -TROUBLESHOOTING GENERATOR
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
DCA-600SSV -TROUBLESHOOTING ENGINE CONTROLLER
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Solution
Sympton
DCA-600SSV-TROUBLESHOOTING DIAGNOSTIC LAMP
Example Error Code
When the MPEC Control
Method of Operation
NOTE PAGE
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV- EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
PART NO. Column
QTY. Column
DCA-600SSV - SUGGESTED SPARE PARTS
DCA-600SSV w/SA6D170AE-1VOLVO ENGINE
1 to 3 Units
Description
GENERATOR ASSY
DCA-600SSV - GENERATOR ASSY
PAGE 64 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - GENERATOR ASSY
QTY. REMARKS
DCA-600SSV - GENERATOR ASSY. CONT
PAGE 66 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
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
DCA-600SSV - CONTROL BOX ASSY. CONT
PAGE 70 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
CIRCUIT BREAKER RESET SWITCH
CHANGE-OVER SWITCH, AMMETER
CHANGE-OVER SWITCH, VOLMETER
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
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
DCA-600SSV - ENGINE AND RADIATOR ASSY
PART NAME
QTY. REMARKS
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
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
SET PLATE, BATTERY SWITCH
WATER TEMPERATURE GAUGE
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
DCA-600SSV - OUTPUTTERMINAL ASSY
PART NAME
SET BOARD, OUTPUT TERMINAL
QTY. REMARKS
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
PAGE 82 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
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
DCA-600SSV - BATTERY ASSY
PART NAME
MUFFLER ASSY
DCA-600SSV - MUFFLER ASSY
PAGE 86 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - MUFFLER ASSY
PART NAME
FUEL TANK ASSY
DCA-600SSV - FUELTANK ASSY
PAGE 88 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - FUELTANK ASSY
PART NAME
ENCLOSURE #1 ASSY
DCA-600SSV - ENCLOSURE #1 ASSY
PAGE 90 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #1 ASSY
PART NAME
QTY. REMARKS
COVER, FRONT FRAME
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
PAGE 92 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PART NAME
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
QTY. REMARKS
ENCLOSURE #2 ASSY
DCA-600SSV - ENCLOSURE #2 ASSY
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DCA-600SSV - ENCLOSURE #2 ASSY
PART NAME
QTY. REMARKS
ENCLOSURE #2 ASSY
DCA-600SSV - ENCLOSURE #2 ASSY. CONT
PAGE 96 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #2 ASSY. CONT
PART NAME
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
DCA-600SSV - RUBBER SEAL ASSY
PART NAME
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
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
TERMS AND CONDITIONS OF SALE - PARTS
Effective October 1
11. Credit issued will be applied to future purchasesonly
SPECIAL EXPEDITING SERVICE
NOTE PAGE
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
HERES HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
MQPOWER
OPERATION AND PARTS MANUAL