Name Plate and Decals ................................ 110-113
Terms and Conditions Of Sale — Parts ............... 114
NOTE
Specification and part
number are subject to
change without notice.
WINGSWINGS
WINGS
WINGSWINGS
PAGE 4 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
N View Parts Diagrams
N Order Parts
N Print Specification Information
Goto www.multiquip.com and click on
Order Par ts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
R Dealer Account Number
R Dealer Name and Address
R Shipping Address (if different than billing address)
R Return Fax Number
R Applicable Model Number
R Quantity, Part Number and Description of Each Part
www.mqpower.com
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 5
When ordering parts, please supply:
R Specify Preferred Method of Shipment:
UPS/Fed Ex DHL
N Priority One Truck
N Ground
N Next Day
N Second/Third Day
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA-600SSK — SPECIFICATIONS
Table 1. Generator Specifications
ModelDCA-600SSK
TypeRevolving field, self ventilated, drip proof, single bearing
Armature ConnectionStar with Neutral
Phase3
Standby Output528 KW (660KVA)
Prime Output480 KW (600 KVA)
Voltages — 1Ø
Voltages — 3Ø
Power Factor0.8
Frequency60 Hz
Frequency Regulation:
No load to full load
Frequency Regulation:
Steady State
InsulationClass F
Sound Level dB(A)
(full load at 23 feet)
Dimensions Approx.
(L x W x H)
Dry Net Weight19,553 lbs. (8,869 kg.)
Isochronous under varying loads from no load to 100% rated load
±0.25 of mean value for constant loads from no load to full load
120,127,139,240,254,277 (Adjustable)
208,220,240,416,440,480 (Reconnectable)
75
204.72 x 64.96 x 98.49 in. (5200 x 1650 x 2,500 mm.)
Table 2. Engine Specifications
KOMATSU SA6D170AE-1
Type direct injection, turbo-charged with after-cooler
No. of Cylinders6 cylinders
Bore x Stroke6.8 in. x 6.8 in. (170 mm x 170 mm)
Rated Output688 HP/1800 rpm
Displacement1411.5 cu. in. (23150 cc)
StartingElectric
Coolant Capacity29.6 gal. (112 liters)
Lube Oil Capacity 16.1 gal. (60.9 liters)
Fuel Consumption
33.9 gal. (128.3L)/hr at full load3/4 load
1/2 load1/4 load
12V- 200 Ah x 2 (24V System)
#2 Diesel Fuel
PAGE 6 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
NOTE PAGE
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 7
DCA-600SSK — DIMENSIONS (TOP AND SIDE)
Figure 1. Dimensions
PAGE 8 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — DIMENSIONS (FRONT , REAR AND DOORS)
Figure 2. Dimensions
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 9
DCA-600SSK — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.
This Owner's Manual has been
NOTE
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
developed to provide complete
instructions for the safe and
efficient operation of the
MQPower
WHISPERWATT™ GENERATOR.
Model
DCA-600SSK
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "
appear throughout this manual, and will be referenced in
conjunction with Safety "
WARNING - LETHAL EXHAUST GASES
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
Hazard Symbols
Message Alert Symbols
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH
if inhaled. NEVER operate this
Gasoline
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
is extremely flammable, and
" which
".
WARNING
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
PAGE 10 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
WARNING - BURN HAZARDS
Engine components can generate extreme
heat. To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of
electrical shock or burn,
severe bodily harm
electrocution,
which can cause
or even
DEATH!
DCA-600SSK — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep
hair
and clothing away from all moving
parts to prevent injury.
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
fingers, hands
CAUTION - RESPIRATORY HAZARDS
,
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
ALWAYS wear approved
protection.
ALWAYS wear approved
hearing
protection.
respiratory
eye
and
This generator, other property,
NOTE
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 11
or the surrounding environment
could be damaged if you do not
follow instructions.
DCA-600SSK — RULES FOR SAFE OPERATION
■
DANGER - READ THIS MANUAL!
Failure to follow instructions in this manual may lead to
serious injury
operated by trained and qualified personnel only! This
equipment is for industrial use only.
The following safety guidelines should always be used when
operating the
General Safety:
■
DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
This equipment should not be operated by persons under
18 years of age.
■
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.
or even
DEATH
! This equipment is to be
DCA-600SSK Whisperwatt™ Generator.
ALWAYS check the machine for loosened threads or bolts
before starting.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
■
High Temperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot!
components can cause serious
burns.
■
The engine of this generator requires an adequate free
flow of cooling air.
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricted it will cause serious
damage to the generator or
engine and may cause injury
to people. The generator
engine gives off DEADLY
carbon monoxide gas.
bodily harm or even death.
NEVER
operate the generator in any
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■
NEVER operate this equipment under the influence or
drugs or alcohol.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
■
Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
NEVER run engine without air filter. Severe engine damage
may occur.
DO NOT leave the generator running in the
unattended.
Refer to the
engine technical questions or information.
ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children.
KOMATSU Engine Owner's Manual
manual mode
for
PAGE 12 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of
electrical shock or burn,
Article 250 (Grounding) of the
National Electrical Code
severe bodily harm
(NEC) provides guide lines for proper grounding and specifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
The following safety recommendations should also be
followed:
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
terminals, insufficient tightening of the terminal connections
may cause damage to the generator
■
ALWAYS make sure generator is properly grounded.
■
NEVER use gas piping as an electrical ground.
■
ALWAYS make sure that electrical circuits are properly
grounded
local codes before operating generator. Severe
DEATH!
per the
National Electrical Code
(NEC) and
injury
by electrocution can result from operating an
ungrounded generator.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
or
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
electrocution,
which can cause
or even
DEATH!
POWER
CORD
(POWER ON)
WET
HANDS
Electrical Safety
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the
National Electrical Code
(NEC) and local codes
before operating generator.
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
■
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 5.
■
NEVER power cables or cords
■
NEVER
stand in water
while AC power from the generator
lay in wate
r.
is being transfer to a load.
Backfeed to a utility system can
cause
electrocution
and or property
damage. DO NOT connect to any
building's electrical system except
through an approved device or after
building main switch is opened.
ALWAYS have a licensed electrician
perform the installation
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 13
DCA-600SSK— RULES FOR SAFE OPERATION
Maintenance Safety
■
The electrical voltage required to operate the generator
can cause severe injury or even death through physical
contact with live circuits. Turn all circuit breakers OFF
before performing maintenance on the generator.
■
NEVER lubricate components or attempt service on a
running machine.
■
ALWAYS disconnect the
before performing service on the generator.
■
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
■
ALWAYS allow the machine a proper amount of time to
cool before servicing.
■
Keep the machinery in proper running condition.
■
Fix damage to the machine immediately and always
replace broken parts.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
■
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
NEGATIVE battery terminal
Battery Safety
Use the following guidelines when handling the battery:
■
■
■■
■
■■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation,
glasses.
Use well insulated gloves when picking up the battery.
DANGER - EXPLOSION HAZARDS
The risk of an explosion exists when performing service
on the battery. To avoid
DO NOT drop the battery. There
is the possibility of risk that the
battery may explode.
DO NOT expose the battery to
open flames, sparks, cigarettes
etc. The battery contains combustible gases and liquids.
If these gases and liquids come in contact with a flame
or spark, an explosion could occur.
ALWAYS keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
ALWAYS keep battery charging and cables in good
working condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
always
wear safety
severe injury
clothing or skin
EYES
, rinse skin or clothing
, rinse eyes immediately with
or
DEATH:
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
PAGE 14 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — RULES FOR SAFE OPERATION
■
Towing & Transporting Safety
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
The following list of safety precautions should be followed
when towing your generator:
CAUTION - FOLLOW TOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting
Transportation
towing your generator.
■
ALWAYS shutdown engine before transporting.
■
Tighten both fuel tank caps securely.
■
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed
guidelines for basic towing techniques.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating.”
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
(DOT)
Safety Towing Regulations
Towing & Transporting Safety
Department of
, before
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
while parked.
■
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
■
Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
■
Avoid sharp turns.
■
Trailer should be adjusted to a level position at all times
when towing.
■
Raise and lock trailer wheel stand in up position when
transporting.
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
■
Place
prevent tipping, while parked.
■
Avoid sharp turns to prevent rolling.
■
DO NOT transport generator with fuel in tank.
Emergencies
chock blocks
support blocks
underneath wheel to prevent rolling,
underneath the trailer’s bumper to
■
Check the tire air pressure on both towing vehicle and
trailer.
Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
Trailer tires should be inflated to 50 psi cold.
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 15
■
■
■
■
ALWAYS know the location of the
nearest
ALWAYS know the location of the
nearest and
ALWAYS know the location of the
nearest phone or
the job site,
ALWAYS have easy access to the phone
numbers of the nearest
and
be invaluable in the case of an emergency.
fire extinguisher
first aid kit
keep a phone on
in case of emergencies.
Fire Department
.
.
Ambulance, Doctor
. This information will
DCA-600SSK — INSTALLATION
DCA-600SSK — INSTALLATION
Figure 3. Typical Generator Grounding Application
PAGE 16 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — INSTALLATION
Outdoor Installation
Install the generator in a area that is free of
bystanders
generator is on secure level ground so that it cannot slide or
shift around. Also install the generator in a manner so that
the exhaust will not be discharged in the direction of nearby
homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to engine
and alternator parts.
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be routed
to a ventilated area.
, and
overhead obstructions
CAUTION - EXHAUST HAZARD
. Make sure the
debris
Generator Grounding
To guard against electrical shock and possible damage to
,
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1.Use one of the following wire types to connect the
generator to earth ground.
a.Copper - 10 AWG (5.3 mm2) or larger.
b.Aluminum - 8 AWG (8.4 mm2) or larger.
2.When grounding the generator (Figure 3) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3.NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat excessively
and possibly burn the valves.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
NOTE
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 17
DCA-600SSK — TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
■
ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
CAUTION - TOWING REGULATIONS
Check with your county or state safety towing regulations
before towing your generator.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 4) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
Check the tire air pressure on both the towing vehicle and
the trailer. Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and working
properly.
Remember the maximum speed unless otherwise posted for
highway towing is 45 MPH. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of terrain.
Place
while parked.
Place
prevent
Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.
Avoid sudden stops and starts. This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
Avoid sharp turns to prevent rolling.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
tipping
underneath wheel to prevent
underneath the trailer's bumper to
, while parked.
rolling,
Figure 4. Generator and Trailer
PAGE 18 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — TRAILER-SAFETY GUIDELINES
5. Frame Width - Measurement is from fender to fender
CAUTION - TRAILER INSPECTION
ALWAYS make sure the trailer is in good operating con-
dition. Check the tires for proper inflation and wear. Also
check the wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions when reading Table 3.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 17 and Figure 67for lug nut tightening
and sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches. Please note that some trailers have a double
axle. This will be shown as 2-6000 lbs., meaning two
axles with a total weight capacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 19
DCA-600SSK — TRAILER-SPECIFICATIONS
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PAGE 20 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 21
DCA-600SSK — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-600SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustrations below and on the preceding pages shows the decals as they appear on the machine.
Should any of these decals become unreadable, replacements can be obtained from your dealer.
PAGE 22 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — OPERATION AND SAFETY DECALS
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 23
DCA-600SSK — OPERATION AND SAFETY DECALS
PAGE 24 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — OPERATION AND SAFETY DECALS
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 25
DCA-600SSK — GENERAL INFORMATION
DCA-600SSK FAMILIARIZATION
Generator
The MQ Power Model DCA-600SSK is a 528 kW
that has been designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Engine Warning Lamp Module
Throttle Lever (Up to S/N 3698616)
Ignition Switch (Up to S/N 3698616)
Engine Speed Switch (S/N 3698617~)
Pre-Heat Button (S/N 3698617~)
Pre-Heat Lamp
Emergency Stop Button
Battery Switch
Generator Control Panel
The “Generator Control Panel” is provided with the following:
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Panel Light
Panel Light Switch
MPEC Module (S/N 3698617~)
Pilot Lamp
Microprocessor Controlled Alarm System
The DCA-600SSK generator is equipped with various alarms
and LED status indicators. These alarms and status indicators
are provided to add safety to the generator when operating
under normal conditions. The DCA-600SSK generator is
designed to shutdown in the event of low oil, high coolant
temperature, low battery and other operation conditions that
may cause severe damage to the generator.
generator
Open Delta Excitation System
The DCA-600SSK generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four connections of the open delta A, B, C, and D.
During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to B,
A to D, and C to D. These three phases of the voltage input
to the voltage regulator are then rectified and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "
according the demands of the required load up to the
horsepower of the engine.
Engine
The DCA-600SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D170AE-1 diesel
This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifications.
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-600SSK
generator are addressed on the following pages.
Electronic Governor System
The electronic governor system is made up of two parts, an
electronic controller that monitors frequency variation as the
load increases and decreases, and an electronic actuator
that controls the engine throttle. The frequency is regulated
at ±0.25 to help protect sensitive equipment.
Open-Delta
" excitation system. The open delta
fixed ceiling
" and responds
engine.
PAGE 26 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — MAJOR COMPONENTS
DCA-600SSK — MAJOR COMPONENTS
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DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 27
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DCA-600SSK — GENERATOR CONTROL PANEL
Up to S/N 3698616
S/N 3698617~
Figure 6. Generator Control Panel
PAGE 28 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-600SSK "
1.Pilot Lamp – Indicates that the generator is working
properly.
2.Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
lit this light will make it easier to read the meters and
gauges. When the generator is not in use be sure to
turn the panel light switch to the OFF position.
3.Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
4.AC Ammeter – Indicates the amount of current the
load is drawing from the generator.
5.AC Voltmeter – Indicates the single phase output
voltage present at the UVWO terminals. .
6.Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals,
or to be switched off.
7.Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off
8.Panel Light Switch – When activated, this switch will
turn on the luminate the control panel.
9.Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage
10.Main Circuit Breaker – This three-pole, 1600 amp main
breaker is provided to protect the UVWO voltage output
terminals from overload.
11.MPEC – Microprocessor
Engine Control Module –
(MPEC) has a vertical row
of status LED's (inset), that
when lit, indicate that an
engine malfunction (fault),
has been detected. When a
fault has been detected the
MPEC will evaluate the fault
and if the fault is major will
shutdown the generator.
Control Panel
" (Figure 6).
During
the engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the controller will shutdown the engine by
initializing the "
Also the MPEC will shutdown the generator in the event of
low oil pressure, high coolant temperature, low coolant level,
and loss of magnetic pickup. These conditions can be
observed by monitoring the LED status indicators on the
front of the MPEC module.
A.Off/Manual/Auto Switch – This switch controls the
B.Low Oil Pressure – Indicates the engine pressure
C.High Coolant Temperature – Indicates the engine
D.Overcrank Shutdown – Indicates the unit has
E.Overspeed Shutdown – Indicates that the engine is
cranking cycle
running of the generator. If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the
immediately.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the
generator will monitor the AC line output from the
building's power source. The generator will engage when
commercial power falls below a preset level.
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a
shut down the generator.
temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a
major
attempted to be started a pre- programmed number of
times, and has failed to start. The number of cycles
and duration are programmable. Typical programmable
start settings is 3 cycles with a 10 second duration.
This is considered a
the generator.
running at an unsafe speed. This is considered a
fault.
, The MPEC will attempt to crank
Over Speed Protection
manual
fault and will shut down the generator.
position, the generator will start
auto
position. In this position the
major
" mode.
major
fault and will
fault and will shut down
major
F.Engine Running – Indicates that engine is running at
a safe operating speed.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 29
DCA-600SSK — ENGINE OPERATING PANEL
Up to S/N 3698616
S/N 3698617~
Figure 7. Engine Operating Panels
PAGE 30 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of the
DCA-600SSK "
1.Tachometer – Indicates engine speed in RPM’s for 60 Hz
operation. This meter should indicate 1800 RPM’s when
the rated load is applied. In addition a built in hour meter
will record the number of operational hours that the
generator has been in use.
2.Engine Warning Display (LED) Module – This module
display’s the following engine failures:
A.Overheat Lamp – This lamp goes ON when
the cooling water temperature rises abnormally.
If the lamp goes ON during normal operation of
the generator, the emergency shutdown device
will stop the engine automatically.
B.Low Oil Pressure Lamp – During normal
operation of the generator this lamp should
remain OFF. When the Auto-OFF/ResetManual switch is set to the “Manual” position
to start the engine, the lamp will illuminate.
After the oil pressure rises after start-up the
lamp will go OFF. If this lamp is ever illuminated (ON)
during normal operation of the generator, the emergency
shutdown device will stop the engine automatically.
Engine Operating Panels
" (Figure 7).
3.Pre-Heat Lamp – Indicates that the glow plugs of the
diesel engine are hot and the engine is ready to be started.
4.Emergency Stop Button – Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a normal means of stopping the engine.
5.Oil Pressure Gauge – During normal operation this gauge
be should read in the “GREEN” zone. When starting the
generator the oil pressure mar read a little bit higher, but
after the engine warms up the oil pressure should return to
the green zone.
6.Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
7.Charging Ammeter Gauge – Indicates the current being
supplied by the engine’s alternator which provides current
for generator’s control circuits and battery charging system.
8.Fuel Level Gauge – Indicates amount of diesel fuel
remaining.
9.Battery Switch – This switch should be set to the ON
position during normal operation. When the engine has
been stop, place this switch in the OFF position. DO NOT
turn this switch during normal operation, it could cause
damage to the electrical equipment.
10.Preheat Switch
plugs in cold weather conditions.
(S/N 3698617~) – Press on to heat glow
C.Low Fuel Level Lamp – When this lamp is
ON, it is time to stop the engine and add fuel.
Remember to let the engine cool before adding
fuel.
D.Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this lamp
goes ON during normal operation of the
generator, stop the engine and fill the battery
with distilled water to the specified level.
E.Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this lamp
goes ON during normal operation of the
generator, stop the engine and replace the air
filter.
11.Engine Speed Switch
changes the engine speed from idle to normal.
(S/N 3698617~) – This switch
12.Ignition Switch (Up to S/N 3698616) – Four position
switch,
pre-heat, stop, run
and
start
. Insert ignition
key to start and stop engine.
13.Throttle Lever (Up to S/N 3698616) - This lever controls
the speed of the engine (low or high).
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 31
DCA-600SSK — OUTPUT TERMINAL OVERVIEW
Output Terminal Familiarization
The “
Output Terminal Panel
the following:
Three 240/139V output receptacles, 50 amp
Three AUX. circuit breakers 240V @50 amps
Two 120V GFCI receptacles, 20 amp
Two (2) GFCI circuit breakers 120V@ 20 amps
Eight (16) output terminal lugs
Figure 8. Output Terminal Panel
” (Figure 8) is provided with
Output Terminal Panel
Shown below (Figure 8) is the
up on the cover to gain access to receptacles and terminal
lugs.
NOTE
Output Terminal Panel
Terminal legs "O" and "Ground"
are considered
bonded grounds
, lift
.
PAGE 32 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — OUTPUT TERMINAL PANEL OVERVIEW
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any
board
position. Each receptacle is protected by a 20 amp
circuit breaker. These breakers are located directly above
the GFCI receptacles. Remember the load output (current)
of both GFCI receptacles is dependent on the load
requirements of the UVWO terminals.
Pressing the
being tripped. Pressing the "
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
reset
button resets the GFCI receptacle after
Test Button
voltage change-over
" (See Figure 9) in
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
UVWO terminals.
Turn the
control panel to obtain the desired voltage. Turning the knob
clockwise will
clockwise will
Figure 11. Voltage Regulator Control Knob
Access to UVWO Terminals
The UVWO terminal lugs are protected by a terminal cover
(Figure 12). Un-lock the locking latch, and lift the terminal
cover to gain access to the UVWO terminals.
voltage regulator control knob
increase
decrease
the voltage, turning the knob counter-
the voltage.
(Figure 11) on the
After the load wires have been securely attached to the
UVWO terminals, place the terminal cover in the down
position and secure the locking latch.
Figure 9. G.F.C.I. Receptacle
Twist Lock Dual Voltage 240/139 VAC Receptacles
There are three 240/139 VAC, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output
terminal panel. These receptacles can be accessed in any
voltage change-over board
position.
Figure 12. Terminal Cover (UVWO Terminals)
Figure 10. 240/139 VAC Twist-Lock
Auxiliary Receptacles
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 33
DCA-600SSK — OUTPUT TERMINAL PANEL OVERVIEW
Connecting Loads
Loads can be connected to the generator by the UVWO terminal
lugs or the convenience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect
a load to the generator.
To protect the UVWO output terminals from overload, a 3pole, 1,600 amp,
sure to switch
prior to starting the engine.
main
circuit breaker is provided. Make
ALL
circuit breakers to the "OFF" position
Over Current Relay
An
over current relay
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the
rent relay must be pressed. The over current relay is located in the control box.
(Figure 14) is connected to the main
reset button
Figure 14. Over Current Relay
on the over cur-
Maximum Power Output (KW)
The entire load connected to the UVWO output terminal lugs,
duplex and auxiliary receptacles must not exceed 528 kW in
standby or 480 kW in prime output.
Figure 13. Connecting Loads
PAGE 34 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK— LOAD APPLICATION
Single Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
NOTE
starting system of the equipment.
If wattage is not given on the equipment's
NOTE
name plate, approximate wattage may be
determined by multiplying nameplate
voltage by the nameplate amperage.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 5.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
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When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up to
the generating set’s rated output (kW) can be used.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Motors and motor-driven equipment
draw much greater current for
starting than during operation.
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DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 35
DANGER - ELECTRICAL SYSTEM HAZARDS
Before connecting this generator to any building’s electrical
system, a
(transfer) switch
licensed electrician
must install an
. Serious damage to the building’s
isolation
electrical system may occur without this transfer switch.
If 3Ø load (kVA) is not given on
the equipment nameplate,
NOTE
approximate 3Ø load output
maybe determined by multiplying
voltage by amperage by 1.732.
DCA-600SSK — GENERATOR OUTPUTS
Generator Output Voltages
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by applying jumpers (6) to the
voltage change-over board
(Figure 15).
Generator Amperage
Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.
To obtain some of the voltages as listed in Table 7 (see
below) will require a fine adjustment using the
lator
(VR)
control knob
located on the control panel.
voltage regu-
Voltage Change-Over Board
The
voltage change-over board
(Figure 15) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
Figure 15. Voltage Change-Over Board
240V Configuration
DANGER - CHANGING JUMPER PLATES
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation. There
exists the possibility of electrocution, electrical shock or
burn, which can cause severe bodily harm or even death!
PAGE 36 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — GENERATOR OUTPUTS/GAUGE READING
Maximum Amps
Table 10 shows the
vide. DO NOT exceed the maximum amps as listed.
maximum
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Figure 17. AC Voltmeter
Change-Over Switch
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How to Read the Output Terminal Gauge.
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
When the voltage change-over board is jumpered for 3Ø,
240V operation (See Figure 16), place the
Change-Over Switch
the
AC Ammeter Change-Over Switch
(Figure 17) to the W-U position and
AC Voltmeter
(Figure 19) to the U
Figure 19. AC Ammeter
Change-Over Switch
or W position to read the output on the selected leg.
Figure 18 AC Voltmeter
Gauge
(Volt reading on W-U Lug)
40
20
0
60
75
A
Figure 20. AC Ammeter
(Amp reading on U lug)
The
NOTE
ammeter
gauges are only active when the
and
voltmeter
UVWO terminals are in use.
Figure 16. Voltage Change-Over Board
240V Configuration
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 37
DCA-600SSK — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the
Voltage Change-Over Board
Voltage Regulator Control Knob
Remember the voltage change-over board determines the
range
of the output voltage and can be configured in two
different positions that provide 6 different output voltages at
the UVWO output terminals. The generator is shipped from
the factory in the 240V configuration. The voltage regulator
(VR) allows the user to increase or decrease the selected
voltage.
3Ø-240V UVWO Terminal Output Voltages
1.Jumper the voltage change-over board for 240V operation
as shown in Figure 21.
and the adjustment of the
.
1Ø-240V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21 .
2.Connect the load wires to the UVWO terminals as shown
in Figure 24.
Figure 23. Voltage Regulator Knob
Figure 21. Voltage Change-Over Board
240V Configuration
2.Connect the load wires to the UVWO terminals as shown
in Figure 22.
1Ø-139V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21.
2.Connect the load wires to the UVWO terminals as shown
in Figure 25.
Figure 22. UVWO Terminal Lugs
3Ø-240V Connections
3.Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
Figure 24. UVWO Terminal Lugs
1Ø-240V Connections
Figure 25. UVWO Terminal Lugs
1Ø-139V Connections
PAGE 38 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1.Jumper the voltage change-over board for 480V operation
as shown in Figure 26. This configuration uses 6 jumper
plates in 3 different positions. Remember there are 2
jumper plates at every position. Every jumper plate
must
1Ø-480V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
2.Connect the load wires to the UVWO terminals as shown
in Figure 28.
be used.
Figure 26. Voltage Change-Over Board
480V Configuration
2.Connect the load wires to the UVWO terminals as shown
in Figure 27.
1Ø-277V UVWO Terminal Output Voltages
1.Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
Figure 28. UVWO Terminal Lugs
1Ø-480V Connections
Figure 27. UVWO Terminal Lugs
3Ø-480V Connections
ALWAYS make sure that the
NOTE
connections to the UVWO
terminals are
The possibility of arcing exists,
that could cause a fire.
secure
and tight.
DANGER - UVWO OUTPUT TERMINALS
NEVER attempt to connect a load to the UVWO output
terminals while the generato
exists of serious injury, electrical shock, electrocution even
death.
r
is operating. The possibility
2.Connect the load wires to the UVWO terminals as shown
in Figure 29.
Figure 29. UVWO Terminal Lugs
1Ø-277V Connections
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 39
DCA-600SSK — PRE-SETUP
Circuit Breakers
To protect the generator from an overload, a 3-pole, 800 amp,
main
circuit breaker is provided to protect the UVWO output
terminals from overload. In addition two single-pole, 20 amp
GFCI
circuit breakers are provided to protect the GFCI
load
receptacles from overload. Three 50 amp
circuit breakers
have also been provided to protect the auxiliary receptacles
from overload. Make sure to switch
ALL
circuit breakers to
Fuel Check
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
the "OFF" position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
Also verify that the oil level is maintained between the two
REFILLING THE FUEL SYSTEM
notches (Figure 30) on the dipstick. See Table 11 for proper
selection of engine oil.
CAUTION - REFUELING THE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
hot
engine can cause a
fire
or
explosion
.
The DCA600SSK series generators may (if equipped with a
trailer or skid) have a
Figure 30. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the oil
drain plug, and refill with the specified amount of oil as outlined
in the Komatsu Engine Owner's Manual. Oil should be
warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
ACEA Specification E2
which consists of an
trailer mounted
can be equipped with a
The skid type fuel system does not use the internal generator
fuel tank.
Use the instructions in this section that applies to your type
of fuel tank system.
ALWAYS
fuel.
DONOT fill the fuel tanks beyond their capacities.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
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Figure 31 Double Fuel Tank System
double fuel tank system
internal
generator fuel tank, and a
(Figure 31),
fuel tank. It is also possible the generator
skid mounted
fill the fuel tank with clean and fresh
fuel tank (Figure 32).
#2 diesel
PAGE 40 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — PRE-SETUP
CAUTION - TRAILER FUEL TANK
Figure 32. Skid Type Fuel Tank System
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1.Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 33.
ALWAYS!
filling secondary internal tank.
fill trailer tank
first
with
#2 diesel fuel
, before
CAUTION - REFUELING THE GENERATOR
ALWAYS
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
2.Trailer Fuel Tank First – The trailer fuel tank is the
place trailer on firm level ground before refueling
Figure 33. Only Fill on Level Ground
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine.
ALWAYS
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 41
fill trailer fuel tank (Figure 34) first.
Figure 34. Fuel Tank Filling Order
NOTE
NOTE
ONLY! use
refueling.
Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.
#2 diesel fuel
when
DCA-600SSK — PRE-SETUP
3.NEVER overfill trailer fuel tank – It is important to
read the trailer fuel gauge when filling trailer fuel tank.
DO NOT wait for fuel to rise in filler neck. See Figure 35.
Figure 35. Full Trailer Tank
CAUTION - REFUELING THE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion . Fuel expands when heated (Figure 36).
4.Once the trailer tank is full, the
secondary inner tank
can be filled (See Figure 36). Notice how the trailer
filler tube level rises when the internal tank is filled.
5.Figure 37 below reflects a full fuel system.
Figure 37. Full Fuel System
6.Fuel from the engine return line will drain into the secondary
internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.
CAUTION - REFUELING SECONDARY FUEL TANK
It is recommended to only fill the internal secondary take to 3/
4 full in order to allow for fuel return, fuel expansion, and to
avoid spillage. See Figure 38 for fuel expansion.
Figure 36. Filling Secondary Internal Fuel Tank
PAGE 42 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
Figure 38. Fuel Expansion
Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)
DCA-600SSK— PRE-SETUP
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
NOTE
may become coated with deposits and cooling efficiency
will be reduced.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
WARNING - BURN HAZARDS
dangerous, so clean only with the engine turned off and the
negative
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of
hot!
coolant exists which
can cause severe burns.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Komatsu Engine Owner's Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
Komatsu Engine Owner's Manual.
Table 12 for engine and radiator, coolant capacities. Make
sure the coolant level in the recovery tank is always between
the "H" and the "L" markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 39) when depressed with the thumb as shown
below.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be
less than 50%.
battery terminal disconnected.
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Operation Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
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Figure 39. Fan Belt Tension
CAUTION - ROTATING PARTS
NEVER place hands near
the belts or fan while the
generator set is running.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 43
DCA-600SSK— PRE-SETUP
Battery
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
DO NOT over fill. Check to see whether the battery cables
are loose. Poor contact may result in poor starting or
malfunctions.
Coating the terminals with an approved battery terminal
treatment compound. Replace battery with only
recommended type battery.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 40) are properly
connected to the battery terminals as shown below. The
RED
cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
Always
keep the terminals firmly tightened.
When connecting battery do the following:
1.NEVER connect the battery cables to the battery
terminals when the
Heat, RUN, or START position. ALWAYS make sure
that the ignition switch is in the STOP position when
connecting the battery.
2.Place a small amount of battery terminal treatment
compound around both battery terminals. This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
NOTE
CAUTION - BATTERY SERVICING SAFETY
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ignition
switch is in either the Pre-
If the battery cable is connected
incorrectly, electrical damage to the
generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
CAUTION - BATTERY SERVICING SAFETY
ALWAYS
reconnect negative terminal LAST.
disconnect the negative terminal FIRST and
Figure 40. Battery Connections
Alternator
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the circuit
will be in short circuit instantaneously resulting the alternator
failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
If any hose (
immediately
fuel
.
or
oil
) lines are defective replace them
PAGE 44 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — GEN. START-UP PROCEDURE (MANUAL)
BEFORE STARTING
1.Place the
in the “OFF” position prior to starting the engine.
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating
.
Direct exhaust away from nearby personnel.
If applicable perform the following:
Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial power.
An external power cord will be required. This capability is an
option
.
Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via commercial
power. An external power cord will be required. This capability
is an
option
.
Generator and Control Panel
2.Connect the load to the
receptacles
connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
WARNING - STARTING THE GENERATOR
door.
3.Tighten the UVWO terminal nuts securely to prevent
NEVER!
or
manually start the engine with the
auxiliary
circuit breakers in the ON (closed) position.
main, GFCI
load wires from slipping out.
main, G.F.C.I.
Figure 42. Main, Aux. and GFCI
Circuit Breakers (OFF)
and
aux.
circuit
UVWO
breakers (Figure 42)
terminals or
as shown in Figure 43. These load
auxiliary
Steps 1 thru 19 are referenced
for Engine Operating Panel up
NOTE
to S/N 3698616. See Figure 41
below. This unit has an
switch
Figure 41. Engine Operating Panel
Up To S/N 3698616
and a
ignition
throttle handle
.
Figure 43. Load Connections
4.Close all engine enclosure doors (Figure 44).
Figure 44. Engine Enclosure Doors
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 45
DCA-600SSK— GENERATOR START-UP PROCEDURE (MANUAL)
5.Set the
battery ON/OFF switch
(Figure 45) to the “ON”
position.
Figure 45. Battery ON/OFF Switch
6.When starting the generator in COLD weather conditions,
turn the
ignition key
Figure 46. Ignition Switch (Pre-Heat)
to the “PREHEAT ” position (Figure 46),
7.Verify that the pre-heat lamp(Figure 47) is lit (ON) before
starting engine.
11. The generator's frequency meter (Figure 50) should be
displaying the 60 cycle output frequency in HERTZ.
Figure 50. Frequency Meter (Hz)
12. The generator's AC-voltmeter (Figure 51) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 52) to increase or decrease the
desired voltage.
Pre-Heat
Lamp
Figure 47. Pre-Heat Lamp
8.Place the
engine throttle lever
in the “LOW” position
(Figure 48).
Figure 48. Engine Throttle Control
9.Turn the ignition key to the “START” position (Figure 49)
and listen for the engine to begin cranking. After the
engine starts release the ignition key.
Figure 51. AC Voltmeter
Figure 52. Voltage Adjust Control Knob
13. The ammeter (Figure 53) will indicate zero amps with no
load applied. When a load is applied, the ammeter will
indicate the amount of current that the load is drawing
from the generator.
Figure 53. Ammeter (No Load)
Figure 49. Engine Ignition Switch
10. Once the engine has started, let it run for 3-5 minutes,
then turn the throttle handle control (Figure 48) to the
“HIGH” position.
PAGE 46 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK— GENERATOR START-UP PROCEDURE (MANUAL)
14. The engine oil pressure gauge (Figure 54) will indicate
the oil pressure (kg/ cm
2)
of the engine. Under normal
17. Place the
“ON” position (Figure 57).
operating conditions the oil pressure is approximately
4
8
kg/cm2
0
ENGINE OIL PRESSURE
Figure 54. Oil Pressure Gauge
15. The
coolant temperature gauge
(Figure 55) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (
Green Zone
).
18. Observe the generator's ammeter (Figure 58) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
WATERTEMP
reading if a load is in use.
main, GFCI
Figure 57. Main, Aux. and GFCI
Circuit Breakers (ON)
, and
aux
. circuit breakers in the
Figure 55. Coolant Temperature Gauge
16. The
tachometer gauge
(Figure 56) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 56. Engine Tachometer Gauge
Figure 58. Ammeter (Load)
19. The generator will run until manually stopped or an
abnormal condition occurs.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 47
Steps 20 thru 26 are referenced
for Engine Operating Panel
S/N 3698617~. See Figure 59
below. This unit does not have
an ignition switch or a throttle
handle. It does have an “
speed switch
conjunction with the MPEC
unit.
circuit breakers in
engine
” that is used in
22. Place the engine speed switch in the “
(Figure 62).
Figure 62. Engine Speed Switch (Low)
23. Place the Auto-Off/Reset-Manual switch in the “
position to start the engine (Figure 63). Once the engine
starts, let the engine run for 1-2 minutes. Listen for any
abnormal noises.
Figure 63. Auto-Off/Reset-Manual Switch
24. Once the engine is warm and the engine is running
properly, place the engine speed switch in the “
position (Figure 64).
LOW
” position
Manual”
HIGH
”
Figure 59. Engine Operating Panel
S/N 3698617~
20. Set the
position.
21. Press and hold the engine preheat button (Figure 59)
until the preheat lamp is lit (ON).
battery ON/OFF switch
Figure 60. Battery ON/OFF Switch
Pre-Heat
Button
Figure 60. Pre-Heat Button/ Lamp
(Figure 60) to the “ON”
Pre-Heat
Lamp
Figure 64. Engine Speed Switch (High)
25. Verify that the "Engine Running" status LED on the MPEC
unit (Figure 65) is "ON" (lit) after the engine has been started.
Figure 65. Engine Running LED (ON)
26. Continue operating the generator as outlined in steps
11 thru 19 (pages 46-47).
PAGE 48 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
Before connecting this generator to any
building’s electrical system, a
electrician
(transfer) switch
must install an
. Serious damage to the
licensed
isolation
The
Engine Speed Switch
position when running in the
set the switch in the proper position can result in damage
to your generator when it turns on.
building’s electrical system may occur
without this transfer switch.
CAUTION - BACKUP GENERATOR USE
When connecting the generator to a isolation (transfer)
NOTE
switch, ALWAYS have power applied to the generator's
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
WARNING - AUTO MODE MAINTENANCE
3.Set the engine speed switch (Figure 67) to the “High”
position.
When running the generator in the AUTO mode, remember
the generator can start up at any time without warning.
NEVER attempt to perform any maintenance when the
generator is in the auto mode.
Figure 67. Engine Speed Switch (High)
CAUTION - ENGINE SPEED SWITCH
must be set to the "High"
Auto-Start
When the generator is set in the “
AUTO ” mode, the generator will
automatically start
commercial power falling below a
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
mode. Failing to
in the event of
When starting generator in AUTO mode use the "
Manual
Start-up" procedure except where noted (see below).
1.Perform steps 1 through 4 in the
(page 45) as outlined in the
2.Set the
battery ON/OFF switch
Before Starting
Manual Starting Procedure
section
.
(Figure 66) to the “ON”
position.
Figure 66. Battery ON/OFF Switch
4.Place the Off/Manual/Auto switch (Figure 68) on the
MPEC unit to the AUTO position.
Figure 68. Off/Manual Auto Switch (AUTO)
5.Continue operating the generator as outlined in steps
11 thru 19 (pages 46-47).
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 49
DCA-600SSK — GENERATOR SHUT-DOWN PROCEDURE
Engine Shutdown Ignition Key (Up to S/N 3698616)
To shutdown the generator use the following procedure:
1.Place both the MAIN, GFCI and LOAD circuit breakers
Engine Shutdown Controller (S/N 3698617~)
To shutdown the generator use the following procedure:
1.Place both the MAIN, GFCI and LOAD circuit breakers
(Figure 69) to the "OFF position".
2. Place the engine speed switch in the “
3.Let the engine cool by running it for 3-5 minutes with no
Figure 69. Main, Aux. and GFCI
Circuit Breakers (OFF)
4.Place the Auto-Off/Reset-Manual switch (Figure 74) to
2.Place the throttle control (Figure 70) in the “LOW” position.
as shown in Figure 67 to the "OFF position".
LOW
(Figure 73).
Figure 73. Engine Speed Switch (High)
load applied.
the
OFF/Reset
position.
” position
Figure 70. Engine Throttle Control
Figure 74. Off/Manual Auto Switch (AUTO)
3.Let the engine cool by running it for 3-5 minutes with no
load applied.
4.Place the ignition key (Figure 71) in the “STOP” position.
5.Verify that the
are "OFF" (not lit).
6.Remove all loads from the generator.
Figure 71. Ignition Key Switch (STOP position)
NEVER stop the engine suddenly except in an emergency.
DO NOT use the emergency stop switch a as method of
5.Remove all loads from the generator.
shutting down the generator. This switch is ONLY to be
used in the event of an emergency.
Emergency Shutdown Procedure
1.PUSH inward the emergency stop button located on the
engine operating panel
(Figure 72) to turn off the
generator in the event of an emergency. This button is
located on either Engine Operating Panel.
NOTE
all
status LED's on the MPEC display
CAUTION - EMERGENCY STOP SWITCH
To disengage the emergency
stop function, pull the emergency
stop button outward to its
original position. This will allow
the generator to operate normally.
Remember the generator will not
start if the emergency stop
button is engaged.
Figure 72. Emergency Stop Button
PAGE 50 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
Use Table 14 shown below as a general checklist to be
performed on a daily basis.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 51
DCA-600SSK — MAINTENANCE
General Inspection
Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel
or oil leaks.
Air Cleaner
Every
50 hours
element.
Outer Element:
1.Loosen wing bolt, remove dust cup, then remove wing
nut and take out element.
2.Clean the inside of the body and cover using a damp
cloth.
3.Blow dry with compressed air (0.69Mpa {7kgf.cm
99.4 PSI} maximum) against the side of the element
along the pleats. Then blow dry against outside along
the pleats, then against inside again.
4.Remove one seal each time the element is cleaned.
5.Replace the outer element after cleaning it 6 times or
after one year. Replace the outer element if indicator is
red even after cleaning it.
6.Check the inner cylinder element clamping nut for
looseness, and retighten if necessary.
: If dust indicator is RED, clean the air cleaner
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
Removing Water from the Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water to
condense. This can be reduced by always keeping the tank
as full as possible.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
2
,
according to the following procedure.
To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.
Service Daily
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
Cleaning the Fuel Strainer
7.If seal washer is damaged or the threads of wing nut are
damaged, replace.
8.Remove evacuator valve and clean it with compressed
air. Reinstall.
Inner element (if equipped)
1.Remove the cover and outer element, then remove the
inner element.
2.Cover the air connector opening (outer side) with clean
cloth or cloth tape.
3.Clean the inside of the body. Remove air connector
opening protection.
4.Install a new inner cylinder element to the cylinder and
tighten the nut.
5.Install element.
6.After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 30.
Check Electric Heater (If equipped)
Before starting in cold weather (once a year), please contact
your Komatsu distributor for inspection. Remove electric
heater from the engine intake manifold and check for
disconnections or dirt. When checking or installing the electric
heater, replace the gasket with a new part.
PAGE 52 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — MAINTENANCE
WARNING - BURN HAZARDS
Allow engine to
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
Flushing Out Radiator and Changing Coolant
1.Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2.Turn water filer cap slowly and remove it.
3.Prepare a container to catch the coolant, then open drain
plug of the radiator or heat exchanger and drain plug of
the engine, and drain the coolant.
4.After draining the coolant, close drain plugs and fill with
tap water.
5.When the water level is near the mouth of the water
filler, open drain plugs and start the engine, and run at
low idling. Keep the engine running at low idling and
flush the radiator for about 10 minutes.
6.Adjust the flow of the water flowing in and draining out
to ensure that the radiator is always full during the
flushing operation. While flushing water through the
system, watch carefully the water inlet hose does not
come out of the radiator filler port.
7.After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
8.After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
9.After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.
12. Remove the corrosion resistor (if equipped) and open
valve.
13. Supply water until it flows over the water filler.
cool
when flushing out
14. Drain the water inside reserve tank, clean the inside of
the reserve tank, then fill with coolant/water mixture to
between the full and low lines.
15. Stop the engine, wait for 3 minutes, add tap water until
the water level reaches near the water filer port, then
tighten the radiator cap.
Changing Oil
1.Make sure the oil is cool before changing.
2.Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
3.Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
4.Using a filter wrench, turn filter cartridge to the left to
remove it. If the filter cartridge is filled with a large
amount of oil, wait 10 minutes or so before removing.
Make sure there is no old gasket stuck on the filter
holder.
5.Tighten drain plug. Clean the filter holder, fill the new
filter cartridge with clean engine oil, coat the packing
and thread of the new filter cartridge with engine oil,
then install it to the filter holder. Tighten until the gasket
surface contacts the seal surface of the filter holder,
then tighten it a further 3/4 to 1 turn.
6.Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7.Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
Replacing Fuel Filter
1.Set the container under the filter cartridge to catch fuel.
2.Using a filter wrench, turn the filter cartridge to the left
to remove it.
3.Clean the filter holder, fill the new filter cartridge with
fuel, coat the packing surface of the filter cartridge with
engine oil, then install the cartridge to the filter holder.
4.When installing, tighten until the packing surface
contacts the seal surface of the filter holder then tighten
a further 2/3 of a turn. If the filter cartridge is tighten too
much, the packing will be damaged and will cause fuel
leakage. Fuel leakage will occur if the filter cartridge is
not tightened enough. Always tighten to the correct
angle.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 53
DCA-600SSK — MAINTENANCE
5.After replacing filter cartridge, loosen air bleed plug.
6.Loosen the knob of feed pump, and pump it up and down
until no bubbles come out with the fuel from air bleed
plug.
7.After bleeding the air, tighten air bleed plug, then push in
the knob of feed pump and lock it in position.
9.Screw in valves at the top of the corrosion resistor.
10. Using a filter wrench, turn the cartridge to the left to
remove it.
11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.
12. Tighten until he packing surface contacts the seal
surface of the filter holder, then tighten a further 2/3 of a
turn.
13. Open valves.
Cleaning Breather Element
Generator Storage:
For storage of the generator for over 30 days, the following
is required:
Fill the fuel tank completely. Treat with fuel stabilizer if
necessary.
Completely drain oil from the crankcase and refill if
necessary with fresh oil.
Clean the entire generator, internal and external.
Disconnect the negative terminals of the battery and
cover it, or remove it from the generator and store it
separately.
If the ambient temperature is expected to drop below
0oC, add antifreeze to the radiator.
Cover the generator set and store in a clean, dry place
Removal From Long Term Storage:
Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.
1.Loosen the clamp, then remove the hose and take out
breather. Wipe off the dirt around the breather. Check
the O-ring, and replace if necessary.
2.Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.
3.Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.
Greasing
1.Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).
Remove the oil filler pipe from the turbocharger oil inlet
port, add 0.5-1L (0.13-0.26 gal) of oil to the turbocharger,
reinstall the oil filler pipe.
Change the oil in engine oil pan.
Replace all the filters.
Flush the inside of the cooling system.
Drain the water from the fuel tank and bleed the air from
the fuel system.
If the engine has not been started for more than one
year, contact your Komatsu distributor to have engine
overhauled.
PAGE 54 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — MAINTENANCE
Jacket Water Heater and Internal Battery Charger 120
VAC Input Receptacles (OPTIONAL)
This generator is equipped with two 120 VAC, 20 amp input
receptacles located on the output terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the
battery charger
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 75). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in
to apply power to jacket water heater. However, if the
generator will be used in
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater simply apply power
to the jacket water heater receptacle via commercial power
using an power cord of adequate size.
.
jacket water heate
hot
climates there is no reason
cold
climates it is always a good
r and i
nternal
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
NOTE
To ensure adequate starting
capability, always have power
applied to the generator's
internal battery charger
.
Figure 75. Battery Charger/Jacket Water
Heater Power Connections
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 55
DCA-600SSK —TRAILER BRAKES MAINTENANCE
Brakes
Trailer brakes should be inspected the
operation. This will allow the brake shoes and drums to seat
properly. After the first 200 mile interval, inspect the brakes
every 3,000 miles
. If driving over rough terrain, inspect the
brakes more frequently.
Air Brake System
Air brakes use compressed air to make the brakes function.
Air brakes are a good and safe way of stopping large and
heavy vehicles. There are many components that make up
an air-brake system, such as the air compressor, air
compressor governor, air storage tanks and air tank drains.
These components need to be maintained by
trained technicians
.
S-Cam Brakes
first 200 miles
qualified
of
and
When the brake pedal is pushed, air is let into each brake
chamber (Figure 76). Air Pressure pushes the rod out, moving
the slack adjuster, thus twisting the brake cam shaft. This
turns the s-cam (so called because it is shaped like the
letter "S").
The s-cam forces the brake shoes away from one another
and presses them against the inside of the brake drum. When
the brake pedal has been released, the s-cam rotates back
and a spring pulls the brake shoes away from the drum,
letting the wheels roll freely.
Air Tank Drains
Compressed air usually has some water in it which is
bad
for the air brake system. Water can freeze in cold weather
and thus cause brake failure. The water tends to collect in
the bottom of the air tank.
to remove water from the air tank
Daily air tank drainage is required
.
Brake Drums (or discs), Linings, and Hoses
Brake drums or discs must not have cracks longer than one
half the width of the friction area. Linings must not be loose,
soaked with oil or grease or be dangerously thin. Mechanical
parts must be in place, not broken or missing. Check that
all air hoses connected to the brake chambers are not worn
or cut due to rubbing.
Air Leaks
Always check for brake air leaks before towing the trailer.
NEVER tow the trailer with an brake air leak problem. The
possibility exists of brake failure.
PAGE 56 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK —TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION - EYESIGHT HAZARD
ALWAYS
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
DO NOT attempt to repair or modify a wheel. DO NOT
install in inner tube to correct a leak through the rim. If the
rim is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are
pressure weekly during use to insure the maximum tire life
and tread wear.
wear safety glasses when
CAUTION - REPAIRING TRAILER WHEELS
hot!
. Check inflation
Suspension
The
leaf suspension
(Figure 77) should be visually inspected
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 17.
springs and associated components
every 6,000
miles
Table 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
NOTE
ALWAYS
when removing or installing force
fitted parts. Failure to comply
may result in serious injury.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 57
wear safety glasses
Figure 77. Major Suspension Components
metI).sbL-.tF(euqroT
TLOB-U"8/353-XAM03-NIM
TLOB-U"61/706-XAM54-NIM
TLOB-U"2/106-XAM54-NIM
DCA-600SSK —TRAILER MAINTENANCE
stnemeriuqeReuqroTnoisnepsuS.71elbaT
SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT
-BOLT ASSEMBLY.
05-XAM03-NIM
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 78. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
stnemeriuqeReuqroTeriT.81elbaT
eziSleehWssaPtsriF
"2152-0204-5356-05
152-0204-5356-05
"3
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
SBL-TF
ssaPdnoceS
SBL-TF
PAGE 58 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
ssaPdrihT
SBL-TF
Figure 78. Wheel Lug Nuts Tightening Sequence
NEVER
use an pneumatic air
gun to tighten wheel lug nuts.
NOTE
Use a
torque wrench
to tighten
lug nuts.
DCA-600SSK — TRAILER-WIRING DIAGRAM
Figure 79. Trailer Wiring Diagram (5-Pin)
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 59
DCA-600SSK — TRAILER-WIRING DIAGRAM
Figure 80. Trailer Wiring Diagram (7-Pin)
PAGE 60 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK —GENERATOR WIRING DIAGRAM
DCA-600SSK — ENGINE WIRING DIA
Figure 81. Generator Wiring Diagram
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 61
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 65
DCA-600SSK — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Troubleshooting) as a basic guideline for troubleshooting the engine. If the problem
cannot be remedied, consult our company's business office or service plant.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 67
DCA-600SSK — TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 21 (Generator Troubleshooting) as a basic guideline for troubleshooting the generator. If the problem
cannot be remedied, consult our company's business office or service plant.
PAGE 68 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — TROUBLESHOOTING (MPEC)
Use Table 22 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the MPEC. If the problem cannot
be remedied, consult our company's business office or service plant.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 69
EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.
4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique
symbol
QTY. Column
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
PAGE 70 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — SUGGESTED SPARE PARTS
DCA-600SSK w/SA6D170AE-1 KOMATSU ENGINE
1 to 3 Units
Qty.P/NDescription
20 ............ 6125817032 ..................... AIR FILTER, INNER & OUTER
88482280104BATTERY CABLE1
98482280304BATTERY CABLE1
107432280504BATTERY CABLE1
117432280904BATTERY CABLE1
127432281104EARTH CABLE1
130347010030HEX. HEAD BOLT4
140208110000HEX. NUT4
150845040114TERMINAL CAP (+)2
160845041004TERMINAL CAP (-)2
170602220205BATTERY SENSOR1
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 95
MUFFLER ASSY.
DCA-600SSK — MUFFLER ASSY.
PAGE 96 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
DCA-600SSK — MUFFLER ASSY.
MUFFLER ASSY.
NOPART NOPART NAMEQTY.REMARKS
18482311002MUFFLER1
20019210020HEX. HEAD BOLT4
37432356504PACKING2
47432356604PACKING1
57432356704PACKING1
60019110030HEX. HEAD BOLT14
70042310000LOCK WASHER14
80042410000HEX. HEAD BOLT14
90019108030HEX. HEAD BOLT8