Multiquip DCA600SSK User Manual
PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA-600SSK
60 Hz GENERATOR
(KOMATSU SA6D170AE-1 DIESEL ENGINE)
PARTS LIST NO. C4875300104C
SERIAL NO. 3692434~
Revision #7 (04/30/10)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — 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 3
TABLE OF CONTENTS
MQ Power DCA-600SSKMQ Power DCA-600SSK
MQ Power DCA-600SSK
MQ Power DCA-600SSKMQ Power DCA-600SSK
AC GeneratorAC Generator
AC Generator
AC GeneratorAC Generator
Proposition 65 Warning .....................................................2
Parts Ordering Procedures ............................................... 5
Specifications Generator/Engine ......................................6
Dimensions (Top and Side) ...............................................8
Dimensions (Front and Rear) ............................................9
Safety Alert Messages Symbols ............................... 10-11
Rules for Safe Operation ........................................... 12-15
Installation ................................................................. 16-17
Towing Rules for Safe Operation .................................... 18
Trailer Safety Guidelines ................................................. 19
Trailer Specifications ................................................. 20-21
Operation and Safety Decals..................................... 22-25
General Information ........................................................ 26
Major Components ......................................................... 27
Generator Control Panel (Up to S/N 3698616) ................ 28
Generator Control Panel (S/N 3698617~) ........................ 28
Generator Control Panel Description ............................... 29
Engine Operating Panel (Up to S/N 3698616)................. 30
Engine Operating Panel (S/N 3698617~) ........................ 30
Engine Operating Panel Description ............................... 31
Output Terminal Panel Overview ................................ 32-34
Load Application ............................................................. 35
Generator Outputs .......................................................... 36
Generator Outputs/Gauge Reading ................................. 37
Output Terminal Panel Connections ........................... 38-39
Pre Setup .................................................................. 40-44
Generator Start-up Procedure (Key Switch) .............. 45-47
Generator Start-up Procedure ( Manual MPEC) ............. 48
Generator Start-up Procedure (Auto MPEC) .................. 49
Generator Shutdown Procedure ...................................... 50
Maintenance .............................................................. 51-55
Trailer Brakes Maintenance ............................................ 56
Trailer Maintenance .................................................... 57-58
Trailer Wiring Diagrams .............................................. 59-60
Generator Wiring Diagram ............................................... 61
Generator Main Breaker Wiring Diagram ......................... 62
Engine Wiring Diagrams ............................................ 63-64
Electronic Governor Controller Wiring Diagram ............... 65
Engine Troubleshooting .............................................. 66-67
Generator Troubleshooting .............................................. 68
Engine Contoller Troubleshooting (MPEC) ...................... 69
Explanation of Codes in Remarks Column ..................... 70
COMPONENT DRACOMPONENT DRA
COMPONENT DRA
COMPONENT DRACOMPONENT DRA
Generator Assembly ......................................... 72-75
Control Box Assembly ....................................... 76-83
Engine Radiator Assembly ................................ 84-87
Engine Operating Panel Assembly ................... 88-89
Output Terminal Assembly ................................ 90-93
Battery Assembly .............................................. 94-95
Muffler Assembly .............................................. 96-97
Fuel Tank Assembly .......................................... 98-99
Enclosure #1 Assembly................................. 100-101
Enclosure #2 Assembly................................. 102-105
Enclosure #3 Assembly................................. 106-107
Enclosure (Rubber Seals) ............................. 108-109
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
Model DCA-600SSK
Type Revolving field, self ventilated, drip proof, single bearing
Armature Connection Star with Neutral
Phase 3
Standby Output 528 KW (660KVA)
Prime Output 480 KW (600 KVA)
Voltages — 1Ø
Voltages — 3Ø
Power Factor 0.8
Frequency 60 Hz
Frequency Regulation:
No load to full load
Frequency Regulation:
Steady State
Insulation Class F
Sound Level dB(A)
(full load at 23 feet)
Dimensions Approx.
(L x W x H)
Dry Net Weight 19,553 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 Cylinders 6 cylinders
Bore x Stroke 6.8 in. x 6.8 in. (170 mm x 170 mm)
Rated Output 688 HP/1800 rpm
Displacement 1411.5 cu. in. (23150 cc)
Starting Electric
Coolant Capacity 29.6 gal. (112 liters)
Lube Oil Capacity 16.1 gal. (60.9 liters)
Fuel Consumption
33.9 gal. (128.3L)/hr at full load 3/4 load
1/2 load 1/4 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 67 for 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 — TRAILER-SPECIFICATIONS
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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)
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