Multiquip DCA-600SSV User Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-600SSV

60 Hz GENERATOR

PARTS LIST NO. C4874303204

Revision #0 (07/13/07)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 3

TABLE OF CONTENTS

MQ Power DCA-600SSVMQ Power DCA-600SSV

MQ Power DCA-600SSV

MQ Power DCA-600SSVMQ Power DCA-600SSV 60 Hz AC Generator60 Hz AC Generator

60 Hz AC Generator

60 Hz AC Generator60 Hz AC Generator

California Proposition 65 Warning ..................................... 2

Reporting Safet Defects ................................................... 3

Table of Contents.............................................................. 4

Parts Ordering Procedures ...............................................5

Specifications ................................................................... 6

Dimensions (Top, Side, Front) .......................................... 7

Safety Alert Messages Symbols ................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-17

Installation ................................................................. 18-19

General Information ........................................................ 20

Major Components ......................................................... 21

Generator Control Panel ............................................ 22-23

Engine Operating Panel ............................................. 24-25

Output Terminal Panel Familiarization ........................ 26-28

Load Application ............................................................. 29

Generator Outputs .......................................................... 30

Generator Outputs/Gauge Reading ................................. 31

Output Terminal Panel Connections ........................... 32-33

Pre Setup .................................................................. 34-38

Generator Start-up Procedure ( Manual MPEC) ........ 39-41

Generator Start-up Procedure (Auto MPEC) .................. 42

Generator Shutdown Procedure ...................................... 43

Maintenance (Engine) ................................................ 44-47

Maintenance (Trailer) ................................................. 48-50

Trailer Wiring Diagram ................................................ 51-52

Generator Wiring Diagram ............................................... 53

Generator Wiring Diagram (Main Breaker) ...................... 54

Engine Wiring Diagram .............................................. 55-56

Engine Troubleshooting .............................................. 57-58

Generator Troubleshooting .............................................. 59

Engine Contoller Troubleshooting (MPEC) ...................... 60

Troubleshooting Diagnostic Lamp ................................... 61

Explanation of Codes in Remarks Column ..................... 62

Suggested Spare Parts .................................................. 63

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .......................................... 64-67

Control Box Assembly ........................................ 68-73

Engine Radiator Assembly ................................. 74-77

Engine Operating Panel Assembly .................... 78-79

Output Terminal Assembly ................................. 80-83

Battery Assembly ............................................... 84-85

Muffler Assembly ............................................... 86-87

Fuel Tank Assembly ........................................... 88-89

Enclosure #1 Assembly...................................... 90-93

Enclosure #2 Assembly...................................... 94-97

Enclosure #3 Assembly...................................... 98-99

Enclosure (Rubber Seals) .............................. 100-101

Nameplate and Decals................................... 102-105

Terms and Conditions Of Sale — Parts ................ 106

NOTE

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Effective:

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■

View Parts Diagrams

■

Order Parts

Goto www.multiquip.com and click on

Order Par ts

to log in and save!

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax.

Domestic (US) Customers dial:

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in

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

Use the

internet

Standard orders

Fax

your order in and qualify for a 2% Discount

Standard orders

Domestic (US) Dealers Call:

and qualify for a 5% Discount

for all orders which include

International Customers

their local Multiquip Representatives for

Note: Discounts Are Subject To Change

should contact

❒❒

❒

❒❒

❒

❒❒

❒

❒❒

❒

❒❒ ❒❒

❒

❒❒

www.mqpower.com

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 5

When ordering parts, please supply:

❒❒

❒

Dealer Account Number Dealer Name and Address Shipping Address (if different than billing address) Return Fax Number Applicable Model Number

All orders are treated as and will ship the same day if received prior

WE ACCEPT ALL MAJOR CREDIT CARDS!

❒❒

Standard Orders

Specify Preferred Method of Shipment:

✓

UPS/Fed Ex

■

Priority One

■

Ground

■ Next Day

✓ DHL ✓

Tru ck

DCA-600SSV — SPECIFICATIONS

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)WK084(AVK006

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)mm561xmm441(.ni05.6x.ni76.5

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)cc

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PAGE 6 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — DIMENSIONS (TOP, SIDE AND FRONT)

TOP VIEW

Figure 1. Dimensions

SIDE VIEW

600

REAR VIEW

(CONTROL PANEL VIEW)

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 7

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm586(.ni79.62G ).mm044(.ni23.71

B).mm596(

.ni63.72H ).mm000,1(.ni73.93

C).mm000,1(.ni73.93I ).mm007,4(.ni40.581

D).mm044(.ni23.71J ).mm500,2(.ni9.87

E).mm099(

.ni89.83K).mm156,1(.ni56

F).mm099(.ni89.83

).mm(.ninoisnemiDretteLecnerefeR).mm(.ninoisnemiD

DCA-600SSV — 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-600SSV

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 8 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

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-600SSV — 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

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 9

DCA-600SSV — 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-600SSV 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 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.

VOLVO Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — 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

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

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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 11

DCA-600SSV— 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. 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.

Turn all circuit breakers OFF

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

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

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 12 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — 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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 13

■

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-600SSV — GENERATOR DECALS

Machine Safety Decals

The DCA-600SSV 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.

Figure 2. Generator Decals

PAGE 14 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR DECALS

Figure 2. Generator Decals

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 15

DCA-600SSV — GENERATOR DECALS

Figure 2. Generator Decals

PAGE 16 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR DECALS

Figure 3. Generator Decals

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 17

DCA-600SSV — INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 18 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — 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 4) 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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 19

DCA-600SSV — GENERAL INFORMATION

DCA-600SSVWhisperwatt™ Series Familiarization Generator

The MQ Power Model DCA-600SSV is a 528 kW

generator

(Figure 5) that is 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 Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

Tachometer/Hour Meter Gauge

■

■■

Water Temperature Gauge / Water Temp. Alarm Lamp

■

■■

Oil Pressure Gauge / Oil Pressure Alarm Lamp

■

■■

Charging Alarm Lamp

■

■■

■

Fuel Level Gauge / Low Fuel Warning Alarm Lamp

■■

■

Pre-Heat Button / Pre-Heat Lamp

■■

■

Air Filter Alarm Lamp

■■

■

Engine Speed Switch

■■

■

Battery Switch

■■

■

Emergency Stop Button

■■

Generator Control Panel

The “Generator Control Panel” is provided with the following:

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

Panel Light/Panel Light Switch

■■

■

3-Pole, 1,600 amp Main Circuit Breaker

■■

■

Engine Control Unit (Computer Controlled)

■■

■

“Control Box” (Located Behind Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Voltage Change-over Board

■■

Open Delta Excitation System

The DCA-600SSV 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.

Engine

The DCA-600SSV is powered by a 4 cycle, water cooled, turbocharged

Engine

requirement for the generator. Reference Table 2 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Electronic Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

Output Terminal Panel

Extension Cables

The “Output Terminal Panel” is provided with the following:

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Four output terminal boards (3Ø power)

■■

■

Ground terminal

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

Open-Delta

" excitation system. The open delta

fixed ceiling

" and responds

VOLVO Model PENTA TAD1642GE Diesel

. This engine is designed to meet every performance

PAGE 20 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — MAJOR COMPONENTS

Tabl e 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Enclosure Assembly

2 Air Cleaner Assembly

3 Muffler Assembly

4 Fuel Tank Assembly

5 Engine and Radiator Assembly

6 Battery Assembly

7 Generator Assembly

8 Output Terminal Assembly

9 Generator Control Panel Assembly

10 Engine Operating Panel Assembly

Figure 5. Major Components

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 21

DCA-600SSV — GENERATOR CONTROL PANEL

AUTO

MANUAL

OFF/RESET

LOW OIL PRESSURE

HIGH COOLANT TEMPERATURE

OVERCRANK OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-600SSV "

Control Panel

" (Figure 6).

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

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

load is drawing from the generator.

5. AC Voltmeter – Indicates the single phase output voltage present at the UVWO terminals. .

PAGE 22 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR CONTROL PANEL

10. Circuit Breaker OFF Lamp – When the circuit

breaker ON switch is placed in the OFF position this lamp will be turned OFF.

11. Circuit Breaker ON Lamp – When the circuit breaker ON switch is placed in the ON position this lamp will be turned ON.

12. Circuit Breaker OFF Switch – Press this switch to place the 1600 amp circuit breaker in the open (OFF) position.

13. Circuit Breaker ON Switch – Press this switch to place the 1600 amp circuit breaker in the closed (ON) position.

14. Auto On/Off Engine Controller (MPEC) – This controller has a vertical row of status LED's (inset), that when lit, indicates that an engine malfunction (fault) has been detected. When a fault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator. During MPEC will attempt to crank the engine for 10 seconds before disengaging.

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 "

cranking cycle

Over Speed Protection

, The

, The MPEC will attempt to crank

" mode.

If the generator is to be connected to a building’s AC power source via an automatic transfer switch (isolation), place the switch in the AUTO position. In this position, should an outage occur, the automatic transfer switch (ATS) will start the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

B. Low Oil Pressure – Indicates the engine pressure

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.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 215°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

D. Overcrank Shutdown – Indicates the unit has

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.

E. Overspeed Shutdown – Indicates that the engine is

running at an unsafe speed. This is considered a fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

major

fault and will

fault and will shut down the generator.

major

fault and will shut down

major

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

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.

manual

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 23

position, the generator will start

DCA-600SSV — ENGINE OPERATING PANEL

TACHOMETER

WATERTEMP.

OILPRESS. FUEL LEVEL

CHARGE

AIRFILTER

BATTERY SWITCH

OFF

PRE-HEAT

LAMP

PRE-HEAT

BUTTON

EMERGENCY

STOP

ENGINE SPEED

HIGH

LOW

Figure 7. Engine Operating Panels

PAGE 24 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-600SSV "

Engine Operating Panels

" (Figure 7).

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.

WATER TEMP.

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. Fuel Level Gauge – Indicates amount of diesel fuel remaining.

8. Battery Switch – This switch should be set to the ON

B. Low Oil Pressure Lamp – During normal operation of the

generator this lamp should remain OFF. When the AutoOFF/Reset-Manual 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

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.

9. Preheat Switch – Press on to heat glow plugs in cold weather conditions.

ever illuminated (ON) during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

C. Low Fuel Level Lamp – When this lamp is

ON, it is time to stop the engine and add fuel.

OIL PRESS.

10. Engine Speed Switch – This switch changes the engine speed from idle to normal.

Hour Meter Switch - Press this pushbutton switch to

11.

activate hour meter. Indicates the number hours equipment has been in operational use.

Remember to let the engine cool before adding fuel.

FUEL LEVEL

D. Charge Lamp – This lamp goes ON when

the electrical charging system is not working properly.

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.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 25

BATTERY

AIR FILTER

DCA-600SSV — OUTPUT TERMINAL FAMILIARIZATION

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 26 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — OUTPUT TERMINAL PANEL FAMILIARIZATION

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

voltage regulator control knob

increase

decrease

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

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

Figure 10. 240/139 VAC Twist-Lock

Auxiliary Receptacles

position.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 27

DCA-600SSV — OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the UVWO terminal lugs or the convenience receptacles. (See Figure 12). 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

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 13) is connected to the main

reset button

Figure 13. Over Current Relay

on the over cur-

Figure 12. Connecting Loads

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.

PAGE 28 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV— 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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 29

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-600SSV — 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).

Maximum Amps

Table 8 shows the vide. DO NOT exceed the maximum amps as listed.

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 14) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

maximum

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Figure 14. 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!

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PAGE 30 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR OUTPUTS/GAUGE READING

How to Read the AC Ammeter and AC Voltage Gauges.

The AC ammeter and AC voltmeter gauges are controlled by the Ac ammeter and AC voltmeter change-over switches.

Both of these switches are located on the generator control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied,

AC Ammeter Gauge Reading

Place the in the U position and observe the current reading (load drain) on the U terminal as indicated in the (Figure 19). This process can be repeated for terminals V

and W. produced at the UVWO terminals lugs. Before taking a reading from either gauge, configure the volt-

age change-over board which produces the desired outputvoltage. When the voltage change-over board is jumpered for 3Ø, 240V operation (See Figure 15).

Figure 18. AC Ammeter

Change-Over Switch

NOTE

Figure 15. Voltage Change-Over Board 240V/3Ø Configuration

AC Ammeter Change-Over Switch

AC Ammeter Gauge

Figure 19. AC Ammeter

(Amp reading on U lug)

The

ammeter

gauges will only show a reading when the

Lugs

are connected to a load

and in use.

and

Output Terminal

(Figure 18)

voltmeter

AC Voltmeter Gauge Reading

Place the

AC Voltmeter Change-Over Switch

(Figure 16) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated in the

AC Voltmeter Gauge

Figure 16. AC Voltmeter

Change-Over Switch

(Figure 17).

Figure 17 AC Voltmeter

Gauge

(Volt reading on W-U Lug)

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 31

DCA-600SSV — 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 20.

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 20 .

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

Figure 22. Voltage Regulator Knob

Figure 20. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

1Ø-139V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20.

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

Figure 21. 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 23. UVWO Terminal Lugs

1Ø-240V Connections

Figure 24. UVWO Terminal Lugs

1Ø-120V Connections

PAGE 32 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 25. 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 25.

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

be used.

Figure 265 Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 26.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

Figure 27. UVWO Terminal Lugs

1Ø-480V Connections

Figure 26. 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.

is operating. The possibility

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

Figure 28. UVWO Terminal Lugs

1Ø-277V Connections

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 33

DCA-600SSV — SETUP

Circuit Breakers

To protect the generator from an overload, a 3-pole, 1600

main

amp,

circuit breaker is provided to protect the UVWO output terminals from overload. In addition two single-pole, 20 amp GFCI receptacles from overload. Three 50 amp

GFCI

circuit breakers are provided to protect the

load

circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch

ALL

circuit

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.

breakers to 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 29) on the dipstick. See Table 9 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

explosion

The DCA600SSV series generators may (if equipped with a trailer or skid) have a

Figure 29. 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 Volvo 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.

DO NOT 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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internal

generator fuel tank, and a

(Figure 30),

fuel tank. It is also possible the generator

skid mounted

fill the fuel tank with clean and fresh

fuel tank (Figure 32).

#2 diesel

Figure 30. Double Fuel Tank System

PAGE 34 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — SETUP

CAUTION - TRAILER FUEL TANK

Figure 31. 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 32.

CAUTION - REFUELING THE GENERATOR

ALWAYS!

fill trailer tank

first

with

#2 diesel fuel

filling secondary internal tank.

DIESEL

FUEL

DIESEL

FUEL

INTERNAL

SECONDARY

TANK

TRAILER

TANK

INTERNAL

FUEL TANK

SIGHT GAUGE

Full 3/4 1/2 1/4 Empty

CORRECT

Figure 33. Fuel Tank Filling Order

, before

INCORRECT

ALWAYS! FILL THE TRAILER FUEL TANK

, BEFORE FILLING

FIRST

INTERNAL FUEL TANK

ALWAYS

place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

Figure 32. Only Fill on Level Ground

2. Trailer Fuel Tank First – The trailer fuel tank is the primary fuel tank and holds a larger capacity of fuel. The fuel in the trailer will be filtered and sent to the engine.

ALWAYS

fill trailer fuel tank (Figure 33) first.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 35

NOTE

ONLY! use

#2 diesel fuel

when

refueling.

Fuel from the secondary inner tank will eventually drain into the

primary trailer tank.

DCA-600SSV — 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 34.

Figure 34. 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 35). Notice how the trailer filler tube level rises when the internal tank is filled.

5. Figure 36 below reflects a full fuel system.

Figure 36. Full Fuel System

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 37 for fuel expansion.

Figure 35. Filling Secondary Internal Fuel Tank

PAGE 36 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

Figure 37. Fuel Expansion

Coolant (Ethylane Glycol [Green] / Water — 50/50 mix)

DCA-600SSV— 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 Volvo 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 Volvo

Engine Owner's Manual.

Table 10 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 38) when depressed with the thumb as shown

below.

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

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When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added.

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Figure 38. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 37

DCA-600SSV— 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 39) 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 39. 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

oil

) lines are defective replace them

PAGE 38 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GEN. START-UP PROCEDURE (MANUAL)

BEFORE STARTING

3. Place 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

4. Connect the load to the

WARNING - STARTING THE GENERATOR

NEVER!

manually start the engine with the

auxiliary

circuit breakers in the ON (closed) position.

main, GFCI

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 door.

G.F.C.I.

Figure 42. GFCI and Auxiliary

Circuit Breakers (OFF)

and

aux.

circuit

breakers (Figure 42) in the

UVWO

terminals or

as shown in Figure 43. These load

auxiliary

1. Press the

Figure 40. Main Circuit Breaker OFF Switch

2. Verify that the

main

circuit

breaker “OFF” switch (Figure 40).

circuit

breaker “OFF” lamp (Figure 41)

is lit (ON).

Figure 41. Main Circuit Breaker OFF Lamp

5. Tighten the UVWO terminal nuts securely to prevent load wires from slipping out.

Figure 43. Load Connections

6. Close all engine enclosure doors (Figure 44).

INCORRECTCORRECT

Figure 44. Engine Enclosure Doors

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 39

DCA-600SSV— GENERATOR START-UP PROCEDURE (MANUAL)

7. Set the position.

battery ON/OFF switch

Figure 45. Battery ON/OFF Switch

(Figure 45) to the “ON”

12. Verify that the "Engine Running" status LED on the MPEC

unit (Figure 50) is "ON" (lit) after the engine has been started.

8. Press and hold the engine preheat button (Figure 46)

until the preheat lamp is lit (ON).

Pre-Heat

Button

Pre-Heat

Lamp

Figure 50. Engine Running LED (ON)

13. The generator's frequency meter (Figure 51) should be displaying the 60 cycle output frequency in HERTZ.

Figure 46. Pre-Heat Button/ Lamp

9. Place the engine speed switch in the “

LOW

” position

(Figure 47).

Figure 47. Engine Speed Switch (Low)

10. Place the Auto-Off/Reset-Manual switch in the “

Manual”

position to start the engine (Figure 48). Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises.

Figure 48. Auto-Off/Reset-Manual Switch

11. Once the engine is warm and the engine is running properly, place the engine speed switch in the “

HIGH

”

position (Figure 49).

Figure 49. Engine Speed Switch (High)

Figure 51. Frequency Meter (Hz)

14. The generator's AC-voltmeter (Figure 52) will display the generator’s output in VOLTS.

Figure 52. AC Voltmeter

15. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 53) to increase or decrease the desired voltage.

Figure 53. Voltage Adjust Control Knob

PAGE 40 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV— GENERATOR START-UP PROCEDURE (MANUAL)

16. The ammeter (Figure 54) will indicate zero amps with no

20. Press the

load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 58. Main Circuit Breaker ON Switch

Figure 54. Ammeter (No Load)

17. The engine oil pressure gauge (Figure 55) will indicate

21. Verify that the

is lit (ON).

the oil pressure (kg/ cm2) of the engine. Under normal operating conditions the oil pressure is approximately

kg/cm2

ENGINE OIL PRESSURE

22. Place the

Figure 55. Oil Pressure Gauge

“OFF” position prior to starting the engine.

main

circuit

breaker “ON” switch (Figure 58).

main

circuit

breaker “ON” lamp (Figure 59)

Figure 59. Main Circuit Breaker ON Lamp

G.F.C.I.

and

aux.

circuit

breakers (Figure 60) in the

18. The

coolant temperature gauge

(Figure 56) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 167 and 203 degrees Fahrenheit (

WATER

Figure 56. Coolant Temperature Gauge

19. The

tachometer gauge

(Figure 57) will indicate the

Green Zone

speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 60. GFCI and Auxiliary

Circuit Breakers (ON)

Figure 57. Engine Tachometer Gauge

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 41

DCA-600SSV — GENERATOR START-UP PROCEDURE (AUTO MODE)

23. Observe the generator's ammeter (Figure 61) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 4 in the (page 38) as outlined in the

2. Set the position.

Figure 61. Ammeter (Load)

24. The generator will run until manually stopped or an abnormal condition occurs.

DANGER - ELECTRICAL SYSTEM HAZARDS

NOTE

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

must install an

. Serious damage to the

building’s electrical system may occur

licensed

isolation

3. Set the engine speed switch (Figure 63) to the “High” position.

without this transfer switch.

Before Starting

Manual Starting Procedure

battery ON/OFF switch

Figure 62. Battery ON/OFF Switch

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.

(Figure 62) to the “ON”

in the event of

Manual

section

CAUTION - BACKUP GENERATOR USE

When connecting the generator to a isolation (transfer)

Figure 63. Engine Speed Switch (High)

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.

4. Place the Off/Manual/Auto switch (Figure 64) on the MPEC unit to the AUTO position.

WARNING - AUTO MODE MAINTENANCE

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

Figure 64. Off/Manual Auto Switch (AUTO)

generator is in the auto mode.

5. Press the circuit breaker

CAUTION - ENGINE SPEED SWITCH

The

Engine Speed Switch

position when running in the

must be set to the "High"

Auto-Start

mode. Failing to

6. Verify that the circuit breaker on lamp (Figure 59) is lit.

7. Continue operating the generator as outlined in the

Manual Start-up

set the switch in the proper position can result in damage to your generator when it turns on.

ON Switch

(Figure 58).

procedure (start at step 10).

PAGE 42 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR SHUT-DOWN PROCEDURE

EMERGENCY

STOP

PUSH

TO STOP

WARNING -

NEVER stop the engine suddenly except in an emergency.

SHUTTING DOWN THE GENERATOR

1. PUSH inward the emergency stop button located on the

engine operating panel

generator in the event of an emergency.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the GFCI and AUX circuit breakers as shown in Figure 42 to the OFF position.

Emergency Shutdown Procedure

2. Place the engine speed switch (Figure 65) in the

“LOW ” (down) position.

Figure 67. Emergency Stop Button

Figure 65. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the

MPEC Control Switch

(Figure 66) in the

OFF/RESET position.

(Figure 67) to turn off the

Figure 66. MPEC Control Switch (Off/Reset)

5. Press the

6. Verify that the

main

circuit

breaker “OFF” switch (Figure 40).

circuit

breaker “OFF” lamp (Figure 41)

is lit (ON).

7. Verify that the

all

status LED on the MPEC display

are OFF (not lit).

8. Remove all loads from the generator.

9. Inspect entire generator for any damage or loosening of components that may have occured during operation.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 43

DCA-600SSV — MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element (Figure 68) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 65) is attached to the air cleaner. When

NOTE

the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

PAGE 44 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

Figure 68. Air Cleaner/Indicator

The air filter should not be changed until the indicator reads “RED”. Dispose of old air filter it may not be cleaned or reused.

DCA-600SSV — MAINTENANCE

Service Daily

If the engine is operating in very conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more

frequently

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 69) wash out any deposits or debris that have accumulated inside the fuel tank.

if these conditions exists.

dusty

dry grass

Fuel Tank Inspection

In addition to cleaning the fuel tank, the following components should be inspected for wear:

■■

Rubber Suspension – look for signs of wear or

■

■■

deformity due to contact with oil. Replace the rubber suspension if necessary.

■■

■

Fuel Hoses – inspect nylon and rubber hoses for signs

■■

of wear, deteration and hardning.

■■

■

Fuel Tank Lining – inspect the fuel tank lining for signs

■■

of excessive amounts of oil or other foreign matter.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. 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.

Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 500 hours or so.



Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Figure 69. Fuel Tank Cleaning



Vent any air

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 45

DCA-600SSV — MAINTENANCE

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 according to the following procedure. See the

Manual

To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

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 29.

Replacing Oil Filter



for details.

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter.

VOLVO Engine

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Radiator Cleaning



The radiator (Figure 70) should be sprayed (cleaned) with a high pressure washer when excessive amouts of dirt and debris have accumulated on the cooling fins or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the fins and tube.

cool

when flushing out



After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Tighten both cocks and replace the overflow tank.



Replace with coolant as recommended by the engine manufaturer.



Close radiator cap tightly.



Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Figure 70. Air Cleaner/Indicator

Generator Storage

For longe term storage of the generator the following is recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.



Completely drain the oil from the crankcase and refill if necessary with fresh oil.



Clean the entire generator, internal and external.



Cover the generating set and store in a clean, dry place.



Disconnect the battery.



Make sure engine coolant is at proper level.



If generator is mounted on a trailer, jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires.

PAGE 46 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — MAINTENANCE

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally 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 71). 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 heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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 71. Battery Charger &

Jacket Water Heater Power Connections

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 47

DCA-600SSV —TRAILER BRAKES MAINTENANCE

Electric Brakes

Electrically actuated brakes (Figure 72) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet. Listed below are some of the advantages that electric brakes have over hydraulic brakes:



Brake system can be manually adjusted to provide the corrected braking capability for varying road and load conditions.



Brake system can be modulated to provide more or less braking force, thus easing the brake load on the towing vehicle.



Brake system has very little lag time between the time the vehicle’s brakes are actuated and the trailer’s brakes are actuated.



Brake system can provide an independent emergency brake system.

Remember in order to properly synchronize the tow vehicle’s braking to the trailer’s braking, can only be accomplished by road testing. Brake lockup, grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 72. displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required. See Table 15. Electric Brake Troubleshooting.

Magnets For All Electric Brakes

To make certain an electrically-operated braking system will function properly, you must have your dealer inspect the magnets at least once a year, or each 12,000 miles. See the brake manual for wear and current inspection instructions.

Brake Controller

The electric brake controller is part of the tow vehicle and is essential in the operation of the electric brakes on the trailer. The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer.

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.

Symptom Possible Cause Solution

No Brakes or Intermittent

Brakes

Weak Brakes or Brakes Pull to

One Side

Locking Brakes Brake components loose, bent or broken? Replace components.

Noisy Brakes System lubricated? Lubricate.

Dragging Brakes Bearings of the wheel adjusted? Adjust.

Figure 72. Electric Brake Components

Table 15. Electric Brake Troubleshooting

Any open circuits or broken wires? Find and correct.

Any short circuits? Find and correct.

Faulty controller? Test and correct.

Any loose connections? Find and repair.

Ground wire secure? Find and secure.

Grease or oil on magnets or linings? Clean or replace.

Connections corroded? Clean and correct cause

Brake drums scored or grooved? Machine or replace.

Brakes synchronized? Correct.

Brake drums out-of-round? Replace.

Brake components correct? Replace and correct.

of corrosion.

PAGE 48 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV —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

Torsion axle systems, the suspension takes place inside the square tube which is filled with highly resilient rubber. It attaches directly to the trailer frame using brackets which are an integral part of the axle assembly (See Figure 70 below).

Visually inspect the mounting hardware for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts immediately. Torque torsion axle mounting hardware as recommended by manufactuer.

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-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 49

wear safety glasses

Figure 70. Major Suspension Components

DCA-600SSV —TRAILER MAINTENANCE

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 71. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 17.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

Table 17. Tire Torque Requirements

Wheel Size First Pass

FT-LBS

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

Second Pass

FT-LBS

Third Pass

FT-LBS

Figure 71. Wheel Lug Nuts Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

NOTE

Use a

torque wrench

lug nuts.

PAGE 50 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

to tighten

DCA-600SSV — TRAILER-WIRING DIAGRAM

Figure 72. Trailer Wiring Diagram (5-Pin)

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 51

DCA-600SSV — TRAILER-WIRING DIAGRAM

Figure 73. Trailer Wiring Diagram (7-Pin)

PAGE 52 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV —GENERATOR WIRING DIAGRAM

DCA-600SSV — ENGINE WIRING DIA

Figure 74. Generator Wiring Diagram

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 53

DCA-600SSV — GENERATOR WIRING DIAGRAM (MAIN BREAKER)

Figure 75. Main Circuit Breaker Wiring Diagram

PAGE 54 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENGINE WIRING DIAGRAM

Figure 76. Engine Wiring Diagram

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 55

DCA-600SSV — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (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.

TABLE 18. ENGINE TROUBLESHOOTING

SYMPTOM POSSIBLE PROBLEM SOLUTION

No fuel? Replenish fuel.

Air in the fuel system? Bleed system.

Water in the fuel system? Remove water from fuel tank.

Fuel pipe clogged? Clean fuel pipe.

Fuel filter clogged? Clean or change fuel filter.

Excessively high viscosity of fuel or engine oil at low temperature?

Fuel with low cetane number? Use the specified fuel.

Use the specified fuel or engine oil.

Engine does not start

Starter does not run.

Fuel leak due to loose injection pipe retaining nut?

Incorrect injection timing? Adjust.

Fuel cam shaft worn? Replace.

Injection nozzle clogged? Clean injection nozzle.

Injection pump malfunctioning? Repair or replace.

Seizure of crankshaft, camshaft, piston, cylinder liner or bearing?

Compression leak from cylinder?

Improper valve timing? Correct or replace timing gear.

Piston ring and liner worn? Replace.

Excessive valve clearance? Adjust.

Battery discharged? Charge battery.

Starter malfunctioning? Repair or replace.

Key switch malfunctioning? Repair or replace.

Tighten nut.

Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.

Wir ing d isconne cted ? C onnect w ir ing.

PAGE 56 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — TROUBLESHOOTING (ENGINE)

TABLE 18. ENGINE TROUBLESHOOTING (CONTINUED)

SYMPTOM POSSIBLE PROBLEM SOLUTION

Fuel filter clogged or dirty? Clean or change.

Air cleaner clogged? Clean or change.

Engine revolution is not smooth.

Either white or blue exhaust gas is observed.

Fuel leak due to loose injection pipe retaining nut?

Injection pump malfunctioning? Repair or replace.

Incorrect nozzle opening pressure?

Injection nozzle stuck or clogged?

Fuel over flow pipe clogged? Clean.

Governor malfunctioning? Repair.

Excessive engine oil? Reduce to the specified level.

Piston ring and liner worn or stuck?

Incorrect injection timing? Adjust.

Deficient compression? Adjust top clearance.

Overload? Lessen the load.

Low grade fuel used? Use the specified fuel.

Tighten nut.

Adjust.

Repair or replace.

Either black or dark gray exhaust gas is observed.

Deficient output.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 57

Fuel filter clogged? Clean or change.

Air cleaner clogged? Clean or change.

Deficient nozzle injection? Repair or replace the nozzle.

Incorrect injection timing? Adjust.

Engine's moving parts seem to be seizing?

Uneven fuel injection? Repair or replace the injection pump.

Deficient nozzle injection? Repair or replace the nozzle.

Compression leak?

Repair or replace.

Replace head gasket, tighten cylinder head bolt, glow plug and nozzle holder.

DCA-600SSV — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

TABLE 19. GENERATOR TROUBLESHOOTING

SYMPTOM POSSIBLE PROBLEM SOLUTION

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Is AVR defective? Replace if necessary.

Defective Rotating Rectifier? Check and replace.

Is engine speed correct? Turn engine throttle lever to "High".

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Confirm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Confirm load requirement and replace.

PAGE 58 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

TABLE 20. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)

Sympton Possible Cause Solution

Low oil level? Fill oil level.

Low oil pressure light is on.

Low coolant level light is on.

High coolant temperture light is on.

Oil pressure sending unit failure? Replace oil pressure sending unit.

Time delay malfuntion in Controller? Refer to dealer.

Wire shorted? Inspect/repair wire.

Low coolant level? Fill coolant level.

Sending unit failure? Replace sending unit.

Low battery voltage? Replace/charge battery.

Fan belt tension incorrect? Tighten/replace fan belt.

Air flow is not circulation through radiator? Clean/repair radiator grill.

Doors open? Close doors.

Exhaust leaking? Replace/repair gaskets or faulty part.

Generator being overloaded? Check/reduce load.

Thermostat failure? Replace thermostat.

Air intake blocked? Clear all air intakes.

Temperature switch failure? Replace temperature switch.

Overcrank light is on.

Overspeed light is on.

Loss of MPU light(s) or on.

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 59

No or low Fuel? Fill fuel level.

Controller needs to be calibrated? Refer to dealer.

RPM engine speed too high? Adjust RPM.

Governor actuator needs to be adjusted? Adjust governor actuator.

Governor controller needs to be adjusted? Adjust governor controller.

Engine Controller needs to be calibrated? Refer to dealer.

Magnetic pick up out of adjustment? Adjust magnetic pick up.

Magnetic pick up dirty? Clean magnetic pick up.

DCA-600SSV— TROUBLESHOOTING (DIAGNOSTIC LAMP)

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. The malfunction can be determined by examining the flashing pattern of the diagnostic lamp (Figure 79) located in the control box.

Figure 79. Diagnostic Panel

Method of Operation

1. Normally, the diagnostic lamp will be

MPEC Control Switch

is placed in the MANUAL

dimly

lit when the

position.

2. If engine trouble occurs, the diagnostic lamp will be

brightly

lit as long as the control switch is left in the

manual position.

Example Error Code 2.

Figure 81 displays the error code for

Figure 81. Error Code High Temperature Intake

NOTE

4. In a situation where several engine malfunctions occur simultaneously, the code for each malfunction will flash one after another in sucession.

5. After all engine related malfunctions have been diagnosed and corrected, and the generator is operating in a normal maner the following code (Figure 82) should be displayed once the reset button is pressed and released

3. The diagnostic lamp will indicate an error code via a flashing pattern on the lamp. This pattern will become visible once the the reset button on the control box has been pushed and released. The error code consists of a series of flashes by the lamp. The error codes are defined as follows:

high temp intake

The error code will flash each

time the reset button is pressed and released until the problems have been corrected.

Figure 82. Normal Operating Code

Example Error Code 1.

Figure 80 displays the error code for

Figure 80. Error Code Low Radiator Coolant

PAGE 60 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

low radiator coolant

For a complete understanding of

NOTE

error codes and troubleshooting procedures, refer to the enclosed engine instruction manual.

NOTE

When the

Switch

MPEC Control

is placed in the AUTO position, the same error codes will apply. Codes will not be

active until the unit is activated.

NOTE PAGE

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 61

DCA-600SSV— 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.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. .... 1 ....

3 12348 HOSE .................... A/R.. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same 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 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.

NOTE

without notice

WASHER, 1/4 IN. ...........

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.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

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

symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

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

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”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

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 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.

PAGE 62 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

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.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-600SSV — SUGGESTED SPARE PARTS

DCA-600SSV w/SA6D170AE-1 VOLVO ENGINE

1 to 3 Units

Qty. P/N Description

20 ............ 6125817032 ..................... AIR FILTER, INNER & OUTER

30 ............ 6003117111 ..................... FUEL FILTER

30 ............ 6002111231 ..................... OIL FILTER

2 .............. 6004111030 ..................... CARTRIDGE, CORROSION RESISTOR

1 .............. 0601810575 ..................... PILOT LAMP, ENGINE TROUBLE

1 .............. 0601810576 ..................... PILOT LAMP, ENGINE TROUBLE

1 .............. 0412222568 ..................... ENGINE FAN BELT

1 .............. 6008155390 ..................... SWITCH STARTER UP TO S/N 3698616

3 .............. 615 .................................. KEY SET, STARTER SWITCH (2) UP TO S/N 3698616

2 .............. 0602122281 ..................... OIL SWITCH

1 .............. 6995621691 ..................... RADIATOR HOSE (UPPER)

1 .............. 6162639650 ..................... RADIATOR HOSE (LOWER)

1 .............. 0605505030 ..................... FUEL CAP

1 .............. 0601820625 ..................... AUTOMATIC VOLTAGE REGULATOR

1 .............. 0601805313 ..................... CIRCUIT BREAKER, 265V, 20A

1 .............. 0601805840 ..................... CIRCUIT BREAKER, 265V, 50A

1 .............. 0601802525 ..................... HANDLE, MAIN CURRENT BREAKER

1 .............. 0601840073 ..................... VOLTAGE REGULATOR (RHEOSTAT)

2 .............. 0601840121 ..................... KNOB, VOLTAGE REGULATOR

1 .............. 0601810072 ..................... PILOT LAMP

2 .............. 0601810261 ..................... BULB PILOT LAMP

1 .............. 23S0311150M ................. CAP, RADIATOR

1 .............. 0602122203 ..................... UNIT OIL PRESSURE

1 .............. 0602123206 ..................... UNIT, WATER TEMPERATURE

1 .............. 0602121052 ..................... CHARGING AMMETER

1 .............. ECU9988N600/800 .......... ECU ENGINE CONTROLLER S/N 3698617~

Part number on this Suggested Spare

NOTE

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 63

Parts List may super cede/replace the P/N shown in the text pages of this book.

GENERATOR ASSY.

DCA-600SSV — GENERATOR ASSY.

PAGE 64 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 4100100202 ROTOR ASSY. .................................. 1 ........ NOT SOLD SEPARETLY

1-1 FIELD ASSY 1 1-2 0601842366 RESISITOR 2 1-3 8171020004 INSULATOR WASHER 6 1-4 8171020504 INSULATOR WASHER 6 1-5 8461070002 FAN 1 1-6 8461614003 COUPLING RING 1 1-7 0010312025 HEX. HEAD BOLT 6 1-8 0042512000 COUPLING DISK ASSY 1 1-9 4163100004 WASHER, COUPLING HUB 1

1-10 8461015003 BALANCING PLATE ......................... 1 ........ PURCHASE ITEM 1-17 AS A SET

1-11 0012120055 HEX. HEAD BOLT 12 1-12 0042620000 SPRING WASHER 12 1-13 8461026023 SET PLATE, RECTIFIER 1 1-14 0601823282 RECTIFIER 2 1-15 0018205020 HEX. SOCKET SHCS 4 1-15A 0040005000 SPRING WASHER 4 1-15B 0041205000 PLAIN WASHER 4 1-16 0010112020 HEAD HEX. BOLT 6 1-16A 0010112000 WASHER, LOCK 6 1-17 0601000209 BALANCING WEIGHT KIT 1 1-18 7431014003 BEARING FLANGE 1 1-19 0072906321 BEARING 1 1-20 0080000105 SNAP RING 1 2 0343207250 HEX. HEAD BOLT 6 2A 0043607000 WASHER, LOCK 6 3 C4130100203 STATOR ASSY. 1 3-1 7431323003 CLAMPER 4 3-2 7431323123 CLAMPER 4 3-3 7431323204 CLAMPER 2 3-4 0061310080 HEX. HEAD BOLT 4 3-4A 0030010000 HEX. NUT 4 3-4B 0040010000 WASHER, LOCK 8 3-4C 0041210000 WASHER, FLAT 4 3-5 0017110020 HEX. HEAD BOLT 8 4 8461315002 END BRACKET 1 5 C4137000003 FIELD ASSY. EXCITER 1 6 0012110075 HEX. HEAD BOLT 6 6A 0042610000 WASHER, LOCK 6 6B 0041210000 WASHER, FLAT 6 7 0845044904 GROMMET 1 8 0016316045 HEX. HEAD BOLT 8 8A 0040016000 WASHER, LOCK 8 8B 0041216000 WASHER, FLAT 8

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 65

GENERATOR ASSY.

DCA-600SSV — GENERATOR ASSY. (CONT.)

PAGE 66 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — GENERATOR ASSY. (CONT.)

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

9 7431310003 COVER, BEARING 1 10 8461312004 GASKET, BEARING 2 11 0016308095 HEX. HEAD BOLT 3 11A 0040008000 SPRING WASHER 3 11B 0041208000 PLAIN WASHER 3 12 0010110016 HEX. HEAD BOLT 1 13 0803000104 PACKING 1 14 8461335003 BRACKET, COVER 1 15 8461334003 COVER, STATOR 1 16 0017106012 HEX. HEAD BOLT 4 17 0017106050 HEX. HEAD BOLT 2 18 8461333003 COVER, EXCITOR 1 19 0017106012 HEX. HEAD BOLT 2 20 0343206170 HEX. HEAD BOLT 16 20A 0043606000 SPRING WASHER 16 21 8461332003 COVER, FAN 1 22 0017106050 HEX. HEAD BOLT 1 23 0605000012 RUBBER SUSPENSION 4 24 0030020000 HEX. NUT 8 24A 0040020000 SPRING WASHER 8 25 C3164701404 SPACER, BEARING 1 26 0070506208 BEARING 1

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 67

CONTROL BOX ASSY.

DCA-600SSV — CONTROL BOX ASSY.

PAGE 68 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4214001602 CONTROL BOX 1 2 0601806153 CURRENT TRANSFORMER, AMMETER 3 3 0017108020 HEX. HEAD BOLT 6 4 C4261506003 SET PANEL, ELECTRIC PARTS 1 5 0017108030 HEX. HEAD BOLT 8 6 0601820658 AUTOMATIC VOLTAGE REGULATOR 1 7 0027105015 MACHINE SCREW 4 8 0601820892 OVER CURRENT RELAY 1 9 0027104015 MACHINE SCREW 2 10 C4261601904 SWITCH BRACKET 1 11 0601810575 DIAGNOSTIC LAMP 1 12 0601831205 RESET SWITCH 1 13 C3267600004 RESISTOR SWITCH 1 14 0027105020 MACHINE SCREW 1 15 003006000 HEX. NUT 1 16 0601830710 CHANGE-OVER SWITCH 1 17 0017106016 HEX. HEAD BOLT 4 18 0601840227 RHEOSTAT (HIGH IDLE SPEED REGULATOR) 1 19 C3262600004 BRACKET 1 20 0017106016 HEX. HEAD BOLT 2 21 0601827655 RELAY 4 21A 0601823109 SOCKET 4 21B 0601824400 HOLDER 4 22 0027104015 MACHINE SCREW 8 23 0601802149 FUSE 1 23A 0601802211 HOLDER, FUSE 1 24 0027103020 MACHINE SCREW 2 25 0601823240 RECTIFIER 1 26 0027105020 MACHINE SCREW 1 27 0601842461 RESISTOR 1 28 0027103020 MACHINE SCREW 1 29 0601828533 RELAY 1 30 0027104016 MACHINE SCREW 2 31 0602202691 CONTROLLER 1 32 0017106016 HEX. HEAD BOLT 3 33 0601815402 TERMINAL BOARD 1 34 0027104020 MACHINE SCREW 2 35 0601815941 TERMINAL BOARD 1 36 0027104020 MACHINE SCREW 2 37 0601807516 CIRCUIT BREAKER, 1600 AMPS 1 38 0015308045 HEX. SOCKET HEAD CAP SCREW 8 38A 0042508000 SPRING WASHER 8 38B 0041208000 PLAIN WASHER 8 39 0010114055 HEX. HEAD BOLT 12 39A 0030014000 HEX. NUT 12 39B 0040014000 SPRING WASHER 12

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 69

CONTROL BOX ASSY.

DCA-600SSV — CONTROL BOX ASSY. (CONT.)

PAGE 70 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

39-C 0041214000 PLAIN WASHER 24 40 7431861113 CHANGE-OVER BOARD, VOLTAGE 1 41 7431852104 CHANGE TERMINAL 10 42 0017108035 HEX. HEAD BOLT 20 43 7971852504 TERMINAL PLATE 7 44 7431853104 CHANGE PLATE 6 45 0801832504 HEX. HEAD BOLT 17 46 0801830904 HEX. HEAD BOLT 3 47 0040020000 SPRING WASHER 20 48 0041420000 PLAIN WASHER 20 49 0010110040 HEX. HEAD BOLT 4 49A 0030010000 HEX. NUT 4 49B 0040010000 SPRING WASHER 4 49C 0041210000 PLAIN WASHER 4 50 C4224004203 CONTROL PANEL 1 51 C4225000213 CONTROL PANEL 1 52 0605011211 PIN 4 53 0601800480 FREQUENCY METER, 220V 1 54 0601800736 AC AMMETER 1 55 0601801040 CHANGE-OVER SWITCH, AMMETER 1 56 0601800252 AC VOLTMETER, 600V 1 57 0601801041 CHANGE-OVER SWITCH, VOLMETER 1 58 0601810072 PILOT LAMP 1 58A 0601810261 BULB 1 59 0601840073 RHEOSTAT (VOLTAGE REGULATOR) 1 60 0601840121 KNOB 1 61 0602202640 ENGINE CONTROLLER 1 62 0027104040 MACHINE SCREW 2 62A 0207004000 HEX. NUT 2 63 0601830765 SWITCH 1 64 0601810161 PANEL LIGHT 1 64A 0601810214 BULB 1 65 0207004000 HEX. NUT 2 66 0601830710 SWITCH, PANEL LIGHT 1 67 0601810476 OFF LAMP, CIRCUIT BREAKER 1 67A 0601810235 BULB 1 68 0601810467 ON LAMP, CIRCUIT BREAKER 1 68A 0601810235 BULB 1 69 0601830498 CIRCUIT BREAKER RESET SWITCH 1 70 0601831224 CIRCUIT BREAKER SWITCH 1 71 C9221100004 HEX. HEAD BOLT 4 71A 0040008000 SPRING WASHER 4 71B 0041208000 PLAIN WASHER 4 71C 0080200007 SNAP RING 4 72 3871824004 STOPPER, CONTROL PANEL 2 73 0041206000 PLAIN WASHER 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 71

.........

CONTROL BOX ASSY.

DCA-600SSV — CONTROL BOX ASSY. (CONT.)

PAGE 72 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — CONTROL BOX ASSY. (CONT.)

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

74 0605010502 SNAP PIN 2 75 8481814503 COVER, CONTROL BOX 1 76 0017108020 HEX. HEAD BOLT 10 77 C4214300904 SIDE PANEL, CONTROL BOX 1 78 0601850349 EMBEDDED PULLS 1 79 C4214301004 SIDE PANEL, CONTROL BOX 1 80 0017108020 HEX. HEAD BOLT 12 81 C4214400404 PANEL, CONTROL BOX 1 82 8481825304 PANEL, CONTROL BOX 1 83 0017108020 HEX. HEAD BOLT 15 84 0017110030 HEX. HEAD BOLT 5 85 0017108020 HEX. HEAD BOLT 3

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 73

ENGINE AND RADIATOR ASSY.

DCA-600SSV — ENGINE AND RADIATOR ASSY.

PAGE 74 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4924200284 ENGINE & RADIATOR SET ....................... 1 ....... TAD1642GE

1A 0602015240 BELT, FAN 1 1B 0602015241 BELT, ALTERNATOR 1 1-1 0602046623 ELEMENT, AIR CLEANER 1 1-2 0602041278 CARTRIDGE, OIL FILTER, FULL-FLOW 2 1-3 0602041276 CARTRIDGE, OIL FILTER, BY-PASS 1 1-4 0602042562 CARTRIDGE, FUEL FILTER 1 1-5 0602042768 CARTRIDGE, FUEL FILTER, PRE-FILTER 1 1-6 0602045161 CARTRIDGE, CORROSION RESISTOR 1 2 C4304200804 ENGINE FOOT 1 3 C4304200704 ENGINE FOOT 1 4 C4304201004 ENGINE FOOT 1 5 C4304200904 ENGINE FOOT 1 6 0013616040 HEX. HEAD BOLT 16 7 0040016000 SPRING WASHER 16 8 0041216000 PLAIN WASHER 16 9 0605000012 RUBBER SUSPENSION 4 10 0030020000 HEX. NUT 8 11 0040020000 SPRING WASHER 8 12 C4311100604 BRACKET, RADIATOR 2 13 0017108025 HEX. HEAD BOLT 4 14 0017110025 HEX. HEAD BOLT 4 15 0010112035 HEX. HEAD BOLT 4 16 0030012000 HEX. NUT 4 17 0040012000 SPRING WASHER 4 18 0041212000 PLAIN WASHER 8 19 6452025504 DRAIN JOINT 1 20 0802024004 PACKING 1 21 0130008000 ELBOW JOINT 1 22 0602022294 HOSE JOINT 2 23 C0321200004 DRAIN JOINT 1 24 C0321300004 CAP 1 25 0019208025 HEX. HEAD BOLT 2 26 0603325017 VALVE 1 27 0265801000 DRAIN HOSE 1 28 0605515074 HOSE BAND 2 29 0602012342 PACKING 1 30 0603306592 ADAPTER 1 31 0603306869 ADAPTER 1 32 0602012071 VALVE 1 33 0602040666 INDICATOR, AIR CLEANER 1 34 0602046007 NIPPLE 1 35 0845035004 PACKING 2 36 0845500304 NIPPLE 2 37 B1368701103 DRAIN JOINT 1 38 0802011104 PLUG 1

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 75

DCA-600SSV — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE AND RADIATOR ASSY.

PAGE 76 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE AND RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

39 0150000018 O RING 1 40 0019206025 HEX. HEAD BOLT 2 41 0130404000 T-JOINT 1 42 0130204000 STREET ELBOW 1 43 0602022291 HOSE JOINT 2 44 C4322600004 DRAIN HOSE 1 45 C4322600104 DRAIN HOSE 1 46 0605515073 HOSE BAND 4 47 C4324100303 BREATHER TANK 1 48 0019208025 HEX. HEAD BOLT 4 49 0603325011 VALVE 1 50 0602022293 HOSE JOINT 1 51 0268800680 BREATHER HOSE 1 52 0268801560 BREATHER HOSE 1 53 0605515138 HOSE BAND 4 54 0191302200 OVERFLOW HOSE 1 55 0605515109 HOSE BAND 1 56 C4358300704 CLAMPER ROD 1 57 C4358300604 CLAMPER ROD 1 58 0012310030 HEX. HEAD BOLT 2 59 0207010000 HEX. HEAD BOLT 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 77

ENGINE OPERATING PANEL ASSY.

DCA-600SSV — ENGINE OPERATING PANEL ASSY.

PAGE 78 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4484002102 SUPPORT LEG 1 2 0017112030 HEX. HEAD BOLT 4 3 0017110030 HEX. HEAD BOLT 2 4 C4352102203 OPERATING PANEL 1 5 0017108020 HEX. HEAD BOLT 4 6 0017108020 HEX. HEAD BOLT 6 7 8085182004 RUBBER COVER 2 8 8085183004 SET FRAME, RUBBER COVER 2 9 0017106020 HEX. HEAD BOLT 12 10 0602101012 BATTERY SWITCH 1 11 0805008804 SET PLATE, BATTERY SWITCH 1 12 0805008704 STAY, BATTERY SWITCH 1 13 0021008070 MACHINE SCREW 2 13A 0040008000 SPRING WASHER 2 13B 0041208000 PLAIN WASHER 2 14 0601830448 PREHEAT BUTTON 1 15 0602103090 PREHEAT LAMP 1 15A 0601810244 BULB 1 16 0602120023 TACHOMETER 1 16A 0602129120 MOUNT KIT 1 17 0602122026 OIL PRESSURE GAUGE 1 17A 0602122026 MOUNT KIT 1 18 0602123023 WATER TEMPERATURE GAUGE 1 18A 0602129121 MOUNT KIT 1 19 0602125055 FUEL GAUGE 1 20 0601831570 SWITCH, HOUR METER 1 21 0602103090 ALARM LAMP 5 21A 0601810244 BULB 5 22 0601830710 CHANGE-OVER SWITCH, SPEED 1 23 0601831954 EMERGENCY STOP BUTTON 1

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 79

OUTPUT TERMINAL ASSY.

DCA-600SSV — OUTPUT TERMINAL ASSY.

PAGE 80 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4231700603 SET BOARD, OUTPUT TERMINAL 1 2 7521860504 OUTPUT TERMINAL 4 3 7521850504 BRACKET, OUTPUT TERMINAL 4 4 0010112040 HEX. HEAD BOLT 8 4A 0030012000 HEX. NUT 8 4B 0040012000 SPRING WASHER 8 4C 0041212000 PLAIN WASHER 16 5 0010112045 HEX. HEAD BOLT 8 5A 0030012000 HEX. NUT 8 5B 0040012000 SPRING WASHER 8 5C 0041212000 PLAIN WASHER 16 6 0010112040 HEX. HEAD BOLT 24 6A 0030012000 HEX. NUT 24 6B 0040012000 SPRING WASHER 24 6C 0041212000 PLAIN WASHER 48 7 0801830404 TERMINAL 1 8 0801830904 HEX. HEAD BOLT 1 9 0039320000 HEX. NUT 2 10 0040020000 SPRING WASHER 3 11 0041420000 PLAIN WASHER 4 12 0019112050 HEX. HEAD BOLT 6 12A 0042312000 SPRING WASHER 6 12B 0042412000 PLAIN WASHER 6 13 0601850275 GROMMET 1 14 0601815324 TERMINAL BOARD 1 15 0027104020 MACHINE SCREW 2 16 C4237101304 COVER, OUTPUT TERMINAL 1 17 7971867114 RUBBER SHEET 1 18 7521865804 SET PLATE, RUBBER SHEET 2 19 0019106020 HEX. HEAD BOLT 5 19A 0042306000 SPRING WASHER 5 19B 0042406000 PLAIN WASHER 5 20 0605010660 KNOB 2 21 0207006000 HEX. NUT 2 22 0019112040 HEX. HEAD BOLT 4 23 0042412000 PLAIN WASHER 8 24 0805009804 STAY RUBBER 4 25 0030012000 HEX. NUT 4 26 7521865603 STOPPER 1 27 0019108030 HEX. HEAD BOLT 1 27A 0030008000 HEX. NUT 1 27B 0041208000 PLAIN WASHER 2 28 C4237100504 COVER 1 29 0017108020 HEX. HEAD BOLT 5 30 0601808803 CIRCUIT BREAKER, 20A 2 31 0601808804 CIRCUIT BREAKER, 50A 3

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 81

OUTPUT TERMINAL ASSY.

DCA-600SSV — OUTPUT TERMINAL ASSY. (CONT.)

PAGE 82 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — OUTPUT TERMINAL ASSY. (CONT.)

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

32 C3261600704 BRACKET, CIRCUIT BREAKER 1 32-1 0221200150 RUBBER CUSHION 1 33 0017106030 HEX. HEAD BOLT 2 34 0601812598 RECEPTACLE 2 35 0601812565 RECEPTACLE 3 36 0027104015 MACHINE SCREW 10 3-A 0030004000 HEX. NUT 10 36B 0041204000 PLAIN WASHER 10 37 C4237101203 COVER 1 38 06061851780 GROMMET 2 39 C4237102804 COVER 1 40 C4237400804 BRACKET 1 41 0017106016 HEX. HEAD BOLT 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 83

BATTERY ASSY.

DCA-600SSV — BATTERY ASSY.

PAGE 84 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0168719052 BATTERY 2 2 C9109100704 BATTERY SHEET 2 3 0805007804 BATTERY BAND 2 4 0805006504 BATTERY BOLT 2 5 0037808000 WING NUT 4 6 0040008000 SPRING WASHER 4 7 0041208000 PLAIN WASHER 4 8 C5347600504 BATTERY CABLE 4 9 C4347601704 BATTERY CABLE 1 10 7432280504 BATTERY CABLE 1 11 C4347601904 BATTERY CABLE 1 12 C4347601804 EARTH CABLE 1 13 0347010030 HEX. HEAD BOLT 4 14 0208110000 HEX. NUT 4 15 0845040114 TERMINAL CAP (+) 2 16 0845041004 TERMINAL CAP (-) 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 85

MUFFLER ASSY.

DCA-600SSV — MUFFLER ASSY.

PAGE 86 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4331100802 MUFFLER 1 2 0019210020 HEX. HEAD BOLT 4 3 C4334200904 PACKING 2 4 C4334200904 PACKING 2 5 0019210030 HEX. HEAD BOLT 10 6 0019208020 HEX. HEAD BOLT 6 7 C4334000903 EXHAUST PIPE 1 8 C4334001003 EXHAUST PIPE 1 9 0602325009 SEAL CLAMP 1 10 C4334200504 GASKET 1 11 0010116050 HEX. HEAD BOLT 8 11A 0040016000 SPRING WASHER 8 11B 0041216000 PLAIN WASHER 8 12 C4484100004 COVER 1 13 0012310025 HEX. HEAD BOLT 2 14 0012310030 HEX. HEAD BOLT 4 15 C4334103603 OUTLET PIPE 1 16 C3334200704 GASKET 1 17 0010112050 HEX. HEAD BOLT 4 17A 0030012000 HEX. NUT 4 17B 0040012000 SPRING WASHER 4 17C 0041212000 PLAIN WASHER 8 18 C4331301204 COVER 1 19 0019208025 HEX. HEAD BOLT 4 20 C4331400204 BRACKET 1 21 0019210020 HEX. HEAD BOLT 2 22 0603320132 U BOLT 1 23 0207310000 HEX. NUT 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 87

FUEL TANK ASSY.

DCA-600SSV — FUEL TANK ASSY.

PAGE 88 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4364002203 FUEL TANK 1 1-1 0845500104 CAP, FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 1-3 0264100505 HOSE, FUEL GAUGE 1 1-4 0605515079 HOSE BAND 2 2 0605503023 FUEL SENSOR 1 3 0802120604 PACKING 1 4 C2924300034 FUEL SENDER 1 5 E1924300184 GASKET 1 6 0022905015 MACHINE SCREW 5 7 8225523104 TANK BAND 2 8 0805003414 PAD, TANK BAND 4 9 0017108020 HEX. HEAD BOLT 2 10 0207308000 SELF-LOCKING NUT 2 11 0222100600 TANK SHEET 6 12 0130206000 STREET ELBOW, 1/2 1 13 0134306220 DRAIN PIPE 1 14 0603325026 VALVE 1 15 0132006000 PLUG 1 16 C1367700304 LOCK PLATE 1 17 0019208025 HEX. HEAD BOLT 2 18 0845039604 RUBBER SEAL 1 19 C4367200004 JOINT PIPE 2 20 0603303071 NUT 2 21 0603302071 SLEEVE 2 22 0191403400 SUCTION HOSE 1 23 0191403800 RETURN HOSE 1 24 0605515073 HOSE BANK 4

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 89

ENCLOSURE #1 ASSY.

DCA-600SSV — ENCLOSURE #1 ASSY.

PAGE 90 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4414003302 BASE 1 2 3875116304 FLOOR PANEL 1 3 0019208020 HEX. HEAD BOLT 4 4 C4414100204 FLOOR PANEL 1 5 C4414100304 FLOOR PANEL 1 6 C4414100404 FLOOR PANEL 1 7 0019208020 HEX. HEAD BOLT 32 8 C4414400104 COVER 2 9 0019208020 HEX. HEAD BOLT 4 10 C4414200003 GUIDE PANEL, AIR 1 10A C4494000004 ACOUSTIC SHEET 1 10-1 0314500110 RUBBER SEAL 2 11 0019208020 HEX. HEAD BOLT 9 12 C4414600504 GUIDE PANEL, AIR 1 13 C4414600604 GUIDE PANEL, AIR 1 14 0017108020 HEX. HEAD BOLT 10 15 C4424005003 FRONT FRAME 1 15A C4494102803 ACOUSTIC SHEET 1 16 C4424005303 FRONT FRAME 1 16A C4494102803 ACOUSTIC SHEET 1 17 C4424005502 FRONT FRAME 1 17A C4494102803 ACOUSTIC SHEET 1 18 C4424005402 FRONT FRAME 1 18A C4494102803 ACOUSTIC SHEET 1 19 0019208020 HEX. HEAD BOLT 24 20 C4424300903 GUIDE PANEL, AIR 1 20A 4494102803 ACOUSTIC SHEET 1 21 C4424301003 GUIDE PANEL, AIR 1 21A C4494102803 ACOUSTIC SHEET 1 22 0019208020 HEX. HEAD BOLT 19 23 0019210025 HEX. HEAD BOLT 8 24 C4424204803 COVER, FROM FRAME 1 25 C4424204704 COVER, FROM FRAME 1 25A C4494102204 ACOUSTIC SHEET 1 26 0019208020 HEX. HEAD BOLT 28 27 0845042703 FILLER BRACKET 1 28 0019208020 HEX. HEAD BOLT 4 29 C4424204604 COVER 1 30 0019206016 HEX. HEAD BOLT 6 31 C4424206703 COVER, FRONT FRAME 1 32 0019208020 HEX. HEAD BOLT 14 33 C4434001402 CENTER FRAME 1 34 0010120065 HEX. HEAD BOLT 6 34A 0030020000 HEX. NUT 6 34B 0040020000 SPRING WASHER 6 34C 0041220000 PLAIN WASHER 12

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 91

ENCLOSURE #1 ASSY.

DCA-600SSV — ENCLOSURE #1 ASSY. (CONT.)

PAGE 92 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENCLOSURE #1 ASSY. (CONT.)

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY. REMARKS

35 0010120065 HEX. HEAD BOLT 8 35A 0030020000 HEX. NUT 8 35B 0040020000 SPRING WASHER 8 35C 0041220000 PLAIN WASHER 16 36 C4434200103 COVER 2 37 0017108020 HEX. HEAD BOLT 12 37A 0207008000 HEX. NUT 12 38 C2367700404 COVER 1 39 0019208020 HEX. HEAD BOLT 2 40 C4464102903 ROOF PANEL 1 41 C4464103003 ROOF PANEL 1 42 C4464103103 ROOF PANEL 1 43 0207108000 HEX. NUT 12 44 8452023004 COVER 1 45 0019208020 HEX. HEAD BOLT 2 46 0019208020 HEX. HEAD BOLT 32 47 C4464502404 GUTTER 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 93

ENCLOSURE #2 ASSY.

DCA-600SSV — ENCLOSURE #2 ASSY.

PAGE 94 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4444001303 REAR FRAME 1 2 3875151004 LOUVER PANEL 1 3 0207106000 HEX. NUT 21 4 C4444000103 REAR FRAME 1 5 C4444000203 REAR FRAME 1 6 C4444000303 REAR FRAME 1 7 0017110025 HEX. HEAD BOLT 18 8 0017108020 HEX. HEAD BOLT 5 9 0019210025 HEX. HEAD BOLT 4 10 7975155003 COVER, REAR FRAME 1 10A 3875944104 ACOUSTIC SHEET 1 11 3875151104 LOUVER PANEL 1 12 0207006000 HEX. NUT 16 13 C4444301204 DUCT COVER 1 13A 8495946104 ACOUSTIC SHEET 1 14 0017108020 HEX. HEAD BOLT 17 15 0019208020 HEX. HEAD BOLT 23 16 C4444300703 VISOR 1 17 3875165803 VISOR 1 18 0019208020 HEX. HEAD BOLT 12 19 7975143003 DOOR, REAR FRAME 1 20 C4444201503 DOOR , REAR FRAME 1 21 3875147204 WINDOW PLATE 1 22 3875147304 WINDOW PLATE 1 23 0207306000 SUPER LOCK NUT 12 24 B9114000102 DOOR HANDLE 1 25 0021806015 MACHINE SCREW 4 26 7975146004 DOOR ROD 1 27 7975146104 DOOR ROD 1 28 0845050704 STAY 4 29 0207106000 HEX. NUT 8 30 0805011304 STOPPER, DOOR 1 31 0805011204 STOPPER, DOOR 1 32 0207106000 HEX. NUT 4 33 0845047104 HINGE 2 33A 0845045004 WASHER 2 34 0845047204 HINGE 2 34A 0845045004 WASHER 2 35 0019208020 HEX. HEAD BOLT 6 36 0845031504 CAP 4 37 0601850097 STOPPER 2 38 0025408025 MACHINE SCREW 2 39 0600800320 MANUAL PACK 1 40 0207106000 HEX. NUT 4 41 C4464202303 ROOF PANEL 1 41A C4494501604 ACOUSTIC SHEET 1

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 95

ENCLOSURE #2 ASSY.

DCA-600SSV — ENCLOSURE #2 ASSY. (CONT.)

PAGE 96 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENCLOSURE #2 ASSY. (CONT.)

ENCLOSURE #2 ASSY.

NO PART NO PART NAME QTY. REMARKS

42 C4464202403 ROOF PANEL 1 42A C4494501604 ACOUSTIC SHEET 1 43 C4464202503 ROOF PANEL 1 43A C4494501604 ACOUSTIC SHEET 1 44 C4464501804 GUTTER 1 45 C4464502304 PANEL 1 45A C4494501604 ACOUSTIC SHEET 1 46 0207008000 HEX. NUT 26 47 C4464502204 COVER, ROOF PANEL 1 47A C4494501704 ACOUSTIC SHEET 1 48 C4464502104 COVER, ROOF PANEL 1 48A C4494501704 ACOUSTIC SHEET 1 49 0017108020 HEX. HEAD BOLT 20 50 0019208020 HEX. HEAD BOLT 32 51 C4374200503 COVER, AIR CLEANER 1 51-1 0310000520 RUBBER SEAL 1 52 0017108020 HEX. HEAD BOLT 8 53 C3374200104 COVER, AIR CLEANER 1 54 0017108020 HEX. HEAD BOLT 2 55 0019210025 HEX. HEAD BOLT 4 56 C4464502504 GUTTER 2

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 97

ENCLOSURE #3 ASSY.

DCA-600SSV — ENCLOSURE #3 ASSY.

PAGE 98 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

DCA-600SSV — ENCLOSURE #3 ASSY.

ENCLOSURE #3 ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4454206003 SPLASHER PANEL 1 2 0019110070 HEX. HEAD BOLT 6 2A 0042310000 SPRING WASHER 6 2-B 0042410000 PLAIN WASHER 6 3 C4454102803 SIDE PANEL 1 3A C4494409504 ACOUSTIC SHEET 1 4 C4454102903 SIDE PANEL 1 4A C4494409404 ACOUSTIC SHEET 1 5 C4454103003 SIDE PANEL 1 5A C4494409304 ACOUSTIC SHEET 1 6 C4454103103 SIDE PANEL 1 6A C4494409204 ACOUSTIC SHEET 1 7 C4454004103 SIDE DOOR 1 7A C4494408604 ACOUSTIC SHEET 1 8 C4454004203 SIDE DOOR 1 8A C4494408704 ACOUSTIC SHEET 1 9 C4454004303 SIDE DOOR 1 9A C4494408804 ACOUSTIC SHEET 1 10 C4454004403 SIDE DOOR 1 10A C4494409104 ACOUSTIC SHEET 1 11 3875151204 LOUVER PANEL 2 12 7975151004 LOUVER PANEL 1 13 0207106000 HEX. NUT 28 14 C4454301904 DUCT 1 14A C4494408904 ACOUSTIC SHEET 1 15 C4454302004 DUCT 1 15A C4494409604 ACOUSTIC SHEET 1 16 C4453402104 DUCT 1 16A C4494409004 ACOUSTIC SHEET 1 17 0207106000 HEX. NUT 35 18 B9114000002 DOOR HANDLE 4 19 0825007362 DOOR HANDLE 3 20 0021806015 MACHINE SCREW 28 21 0845046904 HINGE 8 21A 0845045004 WASHER 8 22 0845047004 HINGE 8 22A 0845045004 WASHER 8 23 0019208020 HEX. HEAD BOLT 37 24 0601850097 STOPPER 11 25 0025408025 MACHINE SCREW 11 26 0019208070 HEX. HEAD BOLT 16 27 0845031504 CAP 16

DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 99

RUBBER SEAL ASSY.

DCA-600SSV — RUBBER SEAL ASSY.

PAGE 100 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)

Multiquip DCA-600SSV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual