WHISPERWATTTM SERIES
OPERATION AND PARTS MANUAL
PARTS LIST NO. C4874303204
MODEL DCA-600SSV
PAGE 2 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
PROPOSITION 65WARNING
Diesel engine exhaust and some of
REPORTING SAFETY DEFECTS
64-67
TABLE OF CONTENTS
MQ Power DCA-600SSV 60 Hz AC Generator
COMPONENT DRAWINGS
Choose from three easy options
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Ordering parts has never been easier
Dry Weight
DCA-600SSV - SPECIFICATIONS
Table 1. Generator Specifications
Table 2. Engine Specifications
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - DIMENSIONS TOP, SIDE AND FRONT
TABLE 3. DIMENSIONS
Figure 1. Dimensions
DANGER
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
CAUTION - OVER-SPEED CONDITIONS
DCA-600SSV - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
DANGER - READTHIS MANUAL
General Safety
DCA-600SSV - RULES FOR SAFE OPERATION
DANGER - ELECTROCUTION HAZARDS
Electrical Safety
DCA-600SSV - RULES FOR SAFE OPERATION
Generator Grounding
DANGER - EXPLOSION HAZARDS
Maintenance Safety
Battery Safety
DCA-600SSV- RULES FOR SAFE OPERATION
Emergencies
Towing & Transporting Safety
DCA-600SSV - RULES FOR SAFE OPERATION
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DCA-600SSV - GENERATOR DECALS
Machine Safety Decals
Figure 2. Generator Decals
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
Mounting
DCA-600SSV - INSTALLATION
Outdoor Installation
CAUTION - EXHAUST HAZARD
Generator Control Panel
DCA-600SSV - GENERAL INFORMATION
Generator
Engine Operating Panel
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
DCA-600SSV - MAJOR COMPONENTS
Table 4. Generator Major Components
Figure 5. Major Components
PAGE 22 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - GENERATOR CONTROL PANEL
1. Pilot Lamp - Indicates that the generator is working properly
Figure 6. Generator Control Panel
be turned ON
When the circuit
DCA-600SSV - GENERATOR CONTROL PANEL
lamp will be turned OFF
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DCA-600SSV - ENGINE OPERATING PANEL
BATTERY SWITCH
Figure 7. Engine Operating Panels
C. Low Fuel Level Lamp - When this lamp is
DCA-600SSV - ENGINE OPERATING PANEL
Output Terminal Panel
DCA-600SSV - OUTPUTTERMINAL FAMILIARIZATION
Output Terminal Familiarization
The “Output Terminal Panel ” Figure 8 is provided with the following
Figure 9 G.F.C.I. Receptacle
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
120VAC GFCI Receptacles
Figure 11. Voltage Regulator Control Knob
Over Current Relay
Connecting Loads
Maximum Power Output KW
DCA-600SSV - OUTPUT TERMINAL PANEL FAMILIARIZATION
DANGER - ELECTRICAL SYSTEM HAZARDS
Single Phase Load
Three Phase Load
DCA-600SSV- LOAD APPLICATION
Voltage Change-Over Board
DCA-600SSV - GENERATOR OUTPUTS
Table 7. Generator Available Voltages
Generator OutputVoltages
Figure 15. Voltage Change-Over Board 240V/3Ø Configuration
DCA-600SSV - GENERATOR OUTPUTS/GAUGE READING
AC Ammeter Gauge Reading
ACVoltmeter Gauge Reading
1Ø-240V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
DCA-600SSV - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
Lubrication Oil
DCA-600SSV - SETUP
Table 9. Recommended Motor Oil
Circuit Breakers
refueling
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
CAUTION -TRAILER FUELTANK
Figure 36. Full Fuel System
DCA-600SSV - SETUP
CAUTION - REFUELINGTHE GENERATOR
Figure 34. Full Trailer Tank
Table 10. Coolant Capacity
DCA-600SSV- SETUP
Cleaning the Radiator
Air Cleaner
Wiring
Battery
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
Generator and Control Panel
DCA-600SSV - GEN. START-UP PROCEDURE MANUAL
BEFORE STARTING
CAUTION - LETHAL EXHAUST HAZARD
7. Set the battery ON/OFF switch Figure 45 to the “ON” position
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
Figure 54. Ammeter No Load
DCA-600SSV- GENERATOR START-UP PROCEDURE MANUAL
Figure 58. Main Circuit Breaker ON Switch
Figure 56. Coolant Temperature Gauge
CAUTION - ENGINE SPEED SWITCH
DCA-600SSV - GENERATOR START-UP PROCEDURE AUTO MODE
CAUTION - BACKUP GENERATOR USE
WARNING - AUTO MODE MAINTENANCE
PUSH TO STOP
DCA-600SSV - GENERATOR SHUT-DOWN PROCEDURE
Normal Shutdown Procedure
Emergency Shutdown Procedure
General Inspection
DCA-600SSV - MAINTENANCE
TABLE 14. INSPECTION/MAINTENANCE
Air Cleaner with Dust Indicator
Fuel Addition
Service Daily
Cleaning Inside the Fuel Tank
Cleaning the Fuel Strainer
Replacing Oil Filter
Radiator Cleaning
Air Removal
Check Oil Level
To ensure adequate starting
DCA-600SSV - MAINTENANCE
Brake Controller
DCA-600SSV -TRAILER BRAKES MAINTENANCE
Electric Brakes
Magnets For All Electric Brakes
Tire Wear/Inflation
DCA-600SSV -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
PAGE 50 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV -TRAILER MAINTENANCE
Lug Nut Torque Requirements
Figure 71. Wheel Lug Nuts Tightening Sequence
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
Starter does not run
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING
Engine does not start
smooth
DCA-600SSV -TROUBLESHOOTING ENGINE
TABLE 18. ENGINE TROUBLESHOOTING CONTINUED
Engine revolution is not
POSSIBLE PROBLEM
DCA-600SSV -TROUBLESHOOTING GENERATOR
TABLE 19. GENERATOR TROUBLESHOOTING
SYMPTOM
Sympton
DCA-600SSV -TROUBLESHOOTING ENGINE CONTROLLER
TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Solution
Method of Operation
DCA-600SSV-TROUBLESHOOTING DIAGNOSTIC LAMP
Example Error Code
When the MPEC Control
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
NOTE PAGE
QTY. Column
DCA-600SSV- EXPLANATION OF CODE IN REMARKS COLUMN
NO. Column
PART NO. Column
Description
DCA-600SSV - SUGGESTED SPARE PARTS
DCA-600SSV w/SA6D170AE-1VOLVO ENGINE
1 to 3 Units
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
PAGE 66 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - GENERATOR ASSY. CONT
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
PAGE 70 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - CONTROL BOX ASSY. CONT
DCA-600SSV - CONTROL BOX ASSY. CONT
CIRCUIT BREAKER RESET SWITCH
CHANGE-OVER SWITCH, AMMETER
CHANGE-OVER SWITCH, VOLMETER
PAGE 72 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - CONTROL BOX ASSY. CONT
QTY. REMARKS
DCA-600SSV - CONTROL BOX ASSY. CONT
PART NAME
PAGE 74 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENGINE AND RADIATOR ASSY
ENGINE AND RADIATOR ASSY
CARTRIDGE, OIL FILTER, BY-PASS
DCA-600SSV - ENGINE AND RADIATOR ASSY
PART NAME
QTY. REMARKS
PAGE 76 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENGINE AND RADIATOR ASSY. CONT
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
DCA-600SSV - ENGINE OPERATING PANEL ASSY
SET PLATE, BATTERY SWITCH
WATER TEMPERATURE GAUGE
CHANGE-OVER SWITCH, SPEED
PAGE 80 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
QTY. REMARKS
DCA-600SSV - OUTPUTTERMINAL ASSY
PART NAME
SET BOARD, OUTPUT TERMINAL
PAGE 82 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - OUTPUTTERMINAL ASSY. CONT
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
PART NAME
DCA-600SSV - BATTERY ASSY
PAGE 86 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - MUFFLER ASSY
MUFFLER ASSY
PART NAME
DCA-600SSV - MUFFLER ASSY
PAGE 88 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - FUELTANK ASSY
FUEL TANK ASSY
PART NAME
DCA-600SSV - FUELTANK ASSY
PAGE 90 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #1 ASSY
ENCLOSURE #1 ASSY
COVER, FRONT FRAME
DCA-600SSV - ENCLOSURE #1 ASSY
PART NAME
QTY. REMARKS
PAGE 92 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
DCA-600SSV - ENCLOSURE #1 ASSY. CONT
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
ENCLOSURE #2 ASSY
DCA-600SSV - ENCLOSURE #2 ASSY
PART NAME
QTY. REMARKS
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
PAGE 98 - DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09
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
PART NAME
DCA-600SSV - RUBBER SEAL ASSY
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
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
SPECIAL EXPEDITING SERVICE
TERMS AND CONDITIONS OF SALE - PARTS
Effective October 1
11. Credit issued will be applied to future purchasesonly
DCA-600SSV - OPERATION AND PARTS MANUAL - REV. #0 07/13/09 - PAGE
NOTE PAGE
OPERATION AND PARTS MANUAL
HERES HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
MQPOWER