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Multiquip DCA-600SSK manual

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Table of contents for the manual

  • Page 1

    P AR TS AND OPERA TION MANUAL P AR TS AND OPERA TION MANUAL THIS MANU AL MUST A CCOMP ANY THE EQUIPMENT A T ALL TIMES. T o find the latest revision of this publication, visit our website at: www .mqpower .com OPERA TION AND PARTS MANUAL WHISPER W A TT™ SERIES MODEL DCA-600SSK 60 Hz GENERA TOR (KOMA TSU SA6D170AE-1 DIESEL ENGINE) Re vision #7 (04/[...]

  • Page 2

    P A GE 2 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Diesel engine exhaust and some of PROPOSITION 65 W ARNING[...]

  • Page 3

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 3 NO TE P A GE[...]

  • Page 4

    P A GE 4 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) T ABLE OF CONTENTS Specification and part number are subject to change without notice . NOTE MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK AC Generator AC Generator AC Generator AC Generator AC Generator Prop[...]

  • Page 5

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 5 P AR TS ORDERING PR OCEDURES www .mqpo we r .com Or dering par ts has never been easier! Choose fr om three easy options: WE A CCEPT ALL MAJOR CREDIT CARDS! When or dering par ts, please supply: R Dealer Account Number R Dealer Name and Address R Shipping Address (if d[...]

  • Page 6

    P A GE 6 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — SPECIFICA TIONS T able 1. Generat or Specifications Model DCA-600SSK T y pe Rev olving field, self ventilated, drip proof, single bearing Arm ature Connection Star with Neutral Pha se 3 Standby Output 528 KW (660KV A) Prime Output 480 KW (600 KV A[...]

  • Page 7

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 7 NO TE P A GE[...]

  • Page 8

    P A GE 8 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — DIMENSIONS (T OP AND SIDE) Figure 1. Dimensions[...]

  • Page 9

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 9 Figure 2. Dimensions DCA-600SSK — DIMENSIONS (FRONT , REAR AND DOORS)[...]

  • Page 10

    P A GE 10 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — SAFETY MESSA GE ALER T SYMBOLS Bef ore using this g enerator , ensure that the operating individual has read and understands all instructions in this manual. Safety precautions should be followed at all times when operating this equipment. F ailu[...]

  • Page 11

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 11 DCA-600SSK — SAFETY MESSA GE ALER T SYMBOLS AL W A YS place the Engine ON/OFF switch in the OFF position and remove the ignition key when the pump is not in use. AL W A YS w ear approv ed respirator y protection. AL W A YS wear approv ed eye and hearing protection. [...]

  • Page 12

    P A GE 12 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — R ULES FOR SAFE OPERA TION The following safety guidelines should always be used when operating the DCA-600SSK Whisperwatt™ Generator . General Safety: ■ DO NO T operate or service this equipment before reading this entire manual. The operato[...]

  • Page 13

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 13 DCA-600SSK — R ULES FOR SAFE OPERA TION POWER CORD (POWER ON) WET HANDS During operation of this generator , there exists the possibility of electrocution, electrical shock or burn, which can cause se vere bodil y harm or e ven DEA TH! T o av oid these hazards: NEVE[...]

  • Page 14

    P A GE 14 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK— R ULES FOR SAFE OPERA TION Battery Safety Use the following guidelines when handling the battery: ■ The battery contains acids that can cause injur y to the ey es and skin. T o avoid eye irritation, always wear safety glasses. ■ Use well insul[...]

  • Page 15

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 15 DCA-600SSK — R ULES FOR SAFE OPERA TION Emergencies ■ AL W A YS kno w the location of the nearest fire extinguisher . ■ AL W A YS kno w the location of the nearest and first aid kit . ■ AL W A YS know the location of the nearest phone or keep a phone on the jo[...]

  • Page 16

    P A GE 16 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 3. T ypical Generator Grounding Application DCA-600SSK — INST ALLA TION DCA-600SSK — INST ALLA TION[...]

  • Page 17

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 17 Outdoor Installation Install the generator in a area that is free of debris , bystanders , and overhead obstructions . Make sure the 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[...]

  • Page 18

    P A GE 18 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) T o reduce the possibility of an accident while tr anspor ting the generator on public roads, always make sure the trailer (Figure 4) that suppor ts the generator and the towing v ehicle are in good operating condition and both units are mechanically sound. The[...]

  • Page 19

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 19 Explanation of Chart: This section is intended to provide the user with trailer ser- vice and maintenance inf or mation. The ser vice and mainte- nance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer wi[...]

  • Page 20

    P A GE 20 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — TRAILER-SPECIFICA TIONS s n o i t a c i f i c e p S r e l i a r T . 3 e l b a T L E D O M N O I T A C I L P P A L L E C L E U F M E T S Y S E K A R B R W V G E M A R F H T G N E L E M A R F H T D I W K C A J D N A T S W 0 1 - R L R T , 5 2 2 W D [...]

  • Page 21

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 21 DCA-600SSK — TRAILER-SPECIFICA TIONS ) t ' n o C ( s n o i t a c i f i c e p S . 3 e l b a T L E D O M R E L P U O C S E R I T S L E E H W E L X A S B U H N O I S N E P S U S L A C I R T C E L E W 0 1 - R L R T S S A L C L L A B " 2 E L B A T S U J D A 2 C[...]

  • Page 22

    P A GE 22 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Machine Safety Decals The DCA-600SSK generator is equipped with a n umber of saf ety decals . These decals are provided f or operator saf ety and maintenance inf or mation. The illustrations below and on the preceding pages sho ws the decals as the y appear on [...]

  • Page 23

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 23 DCA-600SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 24

    P A GE 24 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 25

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 25 DCA-600SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 26

    P A GE 26 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — GENERAL INFORMA TION DCA-600SSK F AMILIARIZA TION Generator The MQ P ow er Model DCA-600SSK is a 528 kW generator that has been designed as a high quality por table (requires a trailer f or transpor t) po wer source f or telecom sites, lighting f[...]

  • Page 27

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 27 DCA-600SSK — MAJOR COMPONENTS DCA-600SSK — MAJOR COMPONENTS 4 e l b a T . s t n e n o p m o C r o j a M r o t a r e n e G . O N M E T IN O I T P I R C S E D 1y l b m e s s A r o t a r e n e G 2y l b m e s s A l e n a P l o r t n o C r o t a r e n e G 3y l b m e s [...]

  • Page 28

    P A GE 28 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — GENERA T OR CONTROL P ANEL Figure 6. Generator Control Panel Up to S/N 3698616 S/N 3698617~[...]

  • Page 29

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 29 DCA-600SSK — GENERA T OR CONTROL P ANEL The definitions below describe the controls and functions of the DCA-600SSK " Control Panel " (Figure 6). 1. Pilot Lamp – Indicates that the generator is working properly . 2. Panel Light – Normally used in dark [...]

  • Page 30

    P A GE 30 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENGINE OPERA TING P ANEL Figure 7. Engine Operating Panels Up to S/N 3698616 S/N 3698617~[...]

  • Page 31

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 31 The definitions below describe the controls and functions of the DCA-600SSK " Engine Operating Panels " (Figure 7). 1 . T achometer – Indicates engine speed in RPM’ s f or 60 Hz operation. This meter should indicate 1800 RPM’ s when the rated load is a[...]

  • Page 32

    P A GE 32 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — OUTPUT TERMINAL O VER VIEW Figure 8. Output T erminal P anel Output T erminal Familiarization The “ Output T erminal P anel ” (Figure 8) is provided with the following:  Three 240/139V output receptacles, 50 amp  Three A UX. circuit bre[...]

  • Page 33

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 33 120 V A C GFCI Receptacles There are two 120 V A C , 20 amp GFCI (Duple x Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board position. Each receptacle is protected by a 20 amp circuit breake[...]

  • Page 34

    P A GE 34 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 13. Connecting Loads Connecting Loads Loads can be connected to the generator by the UVWO terminal lugs or the convenience receptacles. (See Figure 13). Make sure to read the operation manual before attempting to connect a load to the generator . T o pro[...]

  • Page 35

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 35 DCA-600SSK— LO AD APPLICA TION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment. Generally , the[...]

  • Page 36

    P A GE 36 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Generator Output V oltages A wide range of voltages are available to supply voltage for many diff erent applications. V oltages are selected by apply- ing jumpers (6) to the voltage change-over board (Figure 15). T o obtain some of the v oltages as listed in T [...]

  • Page 37

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 37 DCA-600SSK — GENERA T OR OUTPUTS/GA UGE READING How to Read the Output T erminal Gauge. The AC ammeter and AC voltmeter change-over switches on the control panel DO NO T effect the generator output. They are provided to help observe how much power is being supplied,[...]

  • Page 38

    P A GE 38 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 21. V oltage Change-Over Board 240V Configuration DCA-600SSK — OUTPUT TERMINAL P ANEL CONNECTIONS UVW O T erminal Output V oltages V arious output voltages can be obtained using the UVW O output ter minal lugs. The v oltages at the terminals are de- pe[...]

  • Page 39

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 39 2. Connect the load wires to the UVWO terminals as shown in Figure 27. DCA-600SSK — OUTPUT TERMINAL P ANEL CONNECTIONS 3Ø-480V UVWO T erminal Output V oltages 1 . Jumper the voltage change-over board for 480V operation as shown in Figure 26. This configuration uses[...]

  • Page 40

    P A GE 40 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole , but DO NO T ov erfill. Make sure the generator is le v el. Also verify that the oil level is maintained between the two notches (Figure 30) on the dipstic k. See T ab le 11[...]

  • Page 41

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 41 DCA-600SSK — PRE-SETUP Refueling Procedure: 1. Level T anks – mak e sure fuel cells are lev el with the ground. F ailure to do so will cause fuel to spill from the tank bef ore reaching full capacity . See Figure 33. 2. T railer Fuel T ank First – The trailer fu[...]

  • Page 42

    P A GE 42 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — PRE-SETUP 3. NEVER o verfill trailer fuel tank – It is impor tant to read the trailer fuel gauge when filling trailer fuel tank. DO NO T w ait f or fuel to rise in filler nec k. See Figure 35. Figure 35. Full T railer T ank Figure 36. Filling S[...]

  • Page 43

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 43 Coolant (Ethylane Gl ycol [Green] / W ater — 50/50 mix) Use only drinkable tap water . If hard water or water with many impurities is used, the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced. An anticorrosion[...]

  • Page 44

    P A GE 44 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK— PRE-SETUP When connecting battery do the following: 1. NEVER connect the battery cables to the battery terminals when the ignition switch is in either the Pre- Heat, R UN, or ST ART position. AL W A YS make sure that the ignition s witch is in the[...]

  • Page 45

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 45 If applicable perform the following: Apply commercial power to the internal battery charger receptacle (to ensure good star ting) via commercial power . An e xternal power cord will be required. This capability is an option . Apply commercial power to the jacket water[...]

  • Page 46

    P A GE 46 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 52. V oltag e Adjust Contr ol Knob Figure 53. Ammeter (No Load) 13. The ammeter (Figure 53) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator [...]

  • Page 47

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 47 DCA-600SSK— GENERA T OR ST ART -UP PROCEDURE (MANU AL) 14 . The engine oil pressure gauge (Figure 54) will indicate the oil pressure (kg/ cm 2 ) of the engine. Under normal operating conditions the oil pressure is approximately Figure 54. Oil Pressure Gauge Figure 5[...]

  • Page 48

    P A GE 48 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Steps 20 thru 26 are referenced f o r Engine Operating P anel S /N 3698617~. See Figure 59 b e lo w . This unit does not hav e an ignition switch or a throttle handle. It does have an “ engine speed switch ” that is used in conjunction with the MPEC unit. N[...]

  • Page 49

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 49 DCA-600SSK — GENERA T OR ST AR T -UP PROCEDURE (A UT O MODE) When star ting generator in AU TO mode use the " Manual Start-up " procedure except where noted (see below). 1 . P erform steps 1 through 4 in the Bef ore Star ting section (page 45) as outlined [...]

  • Page 50

    P A GE 50 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 71. Ignition Key Switch (ST OP position) Engine Shutdown Ignition Key (Up to S/N 3698616) T o shutdo wn the generator use the f ollowing procedure: 1. Place both the MAIN , GFCI and LO AD circuit breakers (Figure 69) to the " OFF position". 3 .[...]

  • Page 51

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 51 Use T a ble 14 shown belo w as a gener al checklist to be performed on a daily basis. DCA-600SSK — MAINTENANCE . 4 1 E L B A T E C N A N E T N I A M / N O I T C E P S N I s r H 0 1 Y L I A D s r H 0 5 2 s r H 0 0 5 s r H 0 0 0 1 E N I G N E s l e v e L d i u l F e n[...]

  • Page 52

    P A GE 52 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — MAINTENANCE General Inspection Prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks. Air Cleaner Ev er y 50 ho[...]

  • Page 53

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 53 DCA-600SSK — MAINTENANCE Flushing Out Radiator and Changing Coolant 1. Stop the engine and allow to cool. Tighten valv e of the corrosion resistor (if equipped). 2. T ur n water filer cap slowly and remo v e it. 3. Prepare a container to catch the coolant, then open[...]

  • Page 54

    P A GE 54 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Generator Storage: For storage of the generator for over 30 days, the following is required:  Fill the fuel tank completely . T reat with fuel stabilizer if necessar y .  Completely drain oil from the crankcase and refill if necessary with fresh oil.  [...]

  • Page 55

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 55 Jacket W ater Heater and Internal Batter y Charger 120 V A C Input Receptac les (OPTIONAL) This generator is equipped with two 120 V AC , 20 amp input receptacles located on the output terminal panel. The purpose of these receptacles is to provide power via commercial[...]

  • Page 56

    P A GE 56 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Figure 76. Hydraulic Brake Components DCA-600SSK —TRAILER BRAKES MAINTENANCE Brakes T r ailer bra kes should be inspected the first 200 miles of operation. This will allo w the brak e shoes and dr ums to seat properly . After the first 200 mile inter val, ins[...]

  • Page 57

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 57 Tires/Wheels/Lug Nuts Tires and wheels are a ve r y impor tant and critical components of the trailer . When specifying or replacing the trailer wheels it is impor tant the wheels, tires, and axle are properly matched. Tire W ear/Inflation Tire inflation pressure is t[...]

  • Page 58

    P A GE 58 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Lug Nut T orque Requirements It is e xtremely impor tant 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[...]

  • Page 59

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 59 DCA-600SSK — TRAILER-WIRING DIA GRAM Figure 79. T railer Wiring Diagram (5-Pin)[...]

  • Page 60

    P A GE 60 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — TRAILER-WIRING DIA GRAM Figure 80. T railer Wiring Diagram (7-Pin)[...]

  • Page 61

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 61 DCA-600SSK —GENERA T OR WIRING DIA GRAM DCA-600SSK — ENGINE WIRING DI A Figure 81. Generator Wiring Diagram[...]

  • Page 62

    P A GE 62 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — GENERA T OR WIRING DIA GRAM (MAIN BREAKER) Figure 82. Main Circuit Breaker Wiring Diagram[...]

  • Page 63

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 63 DCA-600SSK — ENGINE WIRING DIA GRAM Continued on next page Figure 83. Engine Wiring Diagram[...]

  • Page 64

    P A GE 64 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENGINE WIRING DIA GRAM Continued from previous page Figure 84. Engine Wiring Diagram(Continued)[...]

  • Page 65

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 65 DCA-600SSK — ELECTR ONIC GO V . CONTROLLER WIRING DIA GRAM Figure 85. Electronic Governor Controller[...]

  • Page 66

    P A GE 66 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — TR OUBLESHOO TING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use T ab le 20 (Engine T roub leshooting) as a basic guideline for troub leshooting the engine[...]

  • Page 67

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 67 DCA-600SSK — TR OUBLESHOO TING (ENGINE) ) D E U N I T N O C ( G N I T O O H S E L B U O R T E N I G N E . 0 2 E L B A T M O T P M Y S M E L B O R P E L B I S S O P N O I T U L O S t o n s i n o i t u l o v e r e n i g n E . h t o o m s ? y t r i d r o d e g g o l c [...]

  • Page 68

    P A GE 68 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — TR OUBLESHOO TING (GENERA T OR/ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdo wn, use T able 21 (Gener ator T roub leshooting) as a basic guideline f or troublesho[...]

  • Page 69

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 69 DCA-600SSK — TR OUBLESHOO TING (MPEC) ) C E P M ( G N I T O O H S E L B U O R T R E L L O R T N O C E N I G N E . 2 2 E L B A T n o t p m y Se s u a C e l b i s s o Pn o i t u l o S t h g i l e r u s s e r p l i o w o L . n o s i ? l e v e l l i o w o L. l e v e l l[...]

  • Page 70

    P A GE 70 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) EXPLANA TION OF CODE IN REMARKS COLUMN The f ollo wing section e xplains the diff erent symbols and remarks used in the P ar ts section of this manual. Use the help numbers f ound on the back page of the manual if there are any questions . SAMPLE P AR TS LIST N[...]

  • Page 71

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 71 DCA-600SSK w/SA6D170AE-1 K OMA TSU ENGINE 1 to 3 Units Qty . P/ N Description 2 0 ............ 6125817032 ..................... AIR FIL TER, INNER & OUTER 3 0 ............ 6003117111 ..................... FUEL FIL TER 3 0 ............ 6002111231 ..................[...]

  • Page 72

    P A GE 72 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) GENERA TOR ASSY . DCA-600SSK — GENERA T OR ASSY .[...]

  • Page 73

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 73 GENERA TOR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 8181000002 ROT O R ASSY . .................................. 1 ........ INCLUDE ITEMS W/ * 2 FIELD ASSY . 1 3 * 0601842366 RESIST OR ....................................... 4 ........ SMRK 80W 50 K OHMS 4 * 81[...]

  • Page 74

    P A GE 74 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — GENERA T OR ASSY . GENERA TOR ASSY .[...]

  • Page 75

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 75 DCA-600SSK — GENERA T OR ASSY . GENERA TOR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 3 2 0845044904 GROMMET 1 3 3 0016316045 HEX. HEAD BOL T 8 3 3 0040016000 LOCK W ASHER 8 3 3 0041216000 PLAIN W ASHER 8 3 4 7431310003 C O VER, BEARING 1 3 5 8461312004 GASKET , [...]

  • Page 76

    P A GE 76 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — CONTR OL BO X ASSY . CONTROL BO X ASSY .[...]

  • Page 77

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 77 DCA-600SSK — CONTROL BO X ASSY . CONTROL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 8481812502 CONTROL BO X ........................................ 1 ......... S/N 3744467 AND BELOW 1 4215000012 CONTROL BO X ........................................ 1 ....[...]

  • Page 78

    P A GE 78 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — CONTR OL BO X ASSY . CONTROL BO X ASSY .[...]

  • Page 79

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 79 DCA-600SSK — CONTR OL BO X ASSY . CONTROL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 2 6 7971816104 BR A CKET , CIRCUIT BREAKER .............. 1 ......... S/N 3744467 AND BELOW 2 7 7971816304 BR A CKET , CIRCUIT BREAKER .............. 1 ......... S/N 3744467[...]

  • Page 80

    P A GE 80 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — CONTR OL BO X ASSY . CONTR OL BO X ASSY .[...]

  • Page 81

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 81 CONTR OL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 5 3 82608 SW ITCH ................................................... 1 ......... S/ N 3 69 24 3 4~3698616 .............................................................................. REPLACES P/N 060183134[...]

  • Page 82

    P A GE 82 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — CONTR OL BO X ASSY . CONTROL BO X ASSY .[...]

  • Page 83

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 83 CONTROL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 8 4 0602120498 SPEED SENSOR 1 8 5 0601815402 TERMINAL BOARD ................................. 1 ......... S/N 3698617 AND ABO VE 8 6 0027104020 MACHINE SCREW ................................... 2 ......... S/N[...]

  • Page 84

    P A GE 84 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENGINE & RADIA T OR ASSY . ENGINE & RADIA T OR ASSY .[...]

  • Page 85

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 85 DCA-600SSK — ENGINE & RADIA T OR ASSY . ENGINE & RADIA TOR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4924200114 ENGINE ..................................................... 1 ....... SA6D170AE1 2 6162639171 RADIA T OR .................................[...]

  • Page 86

    P A GE 86 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENGINE & RADIA T OR ASSY . ENGINE & RADIA T OR ASSY .[...]

  • Page 87

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 87 DCA-600SSK — ENGINE & RADIA T OR ASSY . ENGINE & RADIA TOR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 3 9 0010108025 HEX. HEAD BOL T 4 4 0 031108160 PLAIN W ASHER ......................................... 4 ....... REPLACES 0041208000 4 1 020108060 HEX. N[...]

  • Page 88

    P A GE 88 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENGINE OPERA TING P ANEL ASSY . ENGINE OPERA TING P ANEL ASSY .[...]

  • Page 89

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 89 DCA-600SSK — ENGINE OPERA TING P ANEL ASSY . ENGINE OPERA TING P ANEL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4484000602 SUPPORT LEG 1 2 012212035 HEX. HEAD BOL T .................................... 4 ......... REPLACES 0010012035 2 0030012000 HEX. NUT 4 2[...]

  • Page 90

    P A GE 90 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY .[...]

  • Page 91

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 91 DCA-600SSK — OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4231700603 SET BOARD , OUTPUT TERMINAL 1 2 7521860504 OUTPUT TERMINAL 4 3 7521850504 B RA CKET , OUTPUT TERMINAL 4 4 0010112040 HEX. HEAD BOL T 8 4 0030012000 HEX. N[...]

  • Page 92

    P A GE 92 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) OUTPUT TERMINAL ASSY . DCA-600SSK — OUTPUT TERMINAL ASSY .[...]

  • Page 93

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 93 DCA-600SSK — OUTPUT TERMINAL ASSY . 2 5 0030012000 HEX. NUT 4 2 6 7521865603 S T OPPER 1 2 7 0010108030 HEX. HEAD BOL T 1 2 7 020108060 HEX. NUT ................................................... 1 ....... REPLACES 0030008000 2 7 0041208000 PLAIN W ASHER ..........[...]

  • Page 94

    P A GE 94 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — B A TTER Y ASSY . BA TTER Y ASSY .[...]

  • Page 95

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 95 DCA-600SSK — B A TTER Y ASSY . BA TTER Y ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 0168719052 B A TTER Y 2 2 0805018904 B A TTER Y SHEET 2 3 0805007804 B A TTER Y BAND 2 4 0805006504 B A TTER Y BOL T 4 5 0037808000 WING NUT 4 6 0040008000 LOCK W ASHER 4 7 0311[...]

  • Page 96

    P A GE 96 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — MUFFLER ASSY . MUFFLER ASSY .[...]

  • Page 97

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 97 DCA-600SSK — MUFFLER ASSY . MUFFLER ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 8482311002 MUFFLER 1 2 0019210020 HEX. HEAD BOL T 4 3 7432356504 P A CKING 2 4 7432356604 P A CKING 1 5 7432356704 P A CKING 1 6 0019110030 HEX. HEAD BOL T 1 4 7 0042310000 LOCK W AS[...]

  • Page 98

    P A GE 98 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — FUEL T ANK ASSY . FUEL T ANK ASSY .[...]

  • Page 99

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 99 DCA-600SSK — FUEL T ANK ASSY . FUEL T ANK ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4364000703 FUEL T ANK .............................................. 1 ......... S/N UP TO 3692433 1 C4364000713 FUEL T ANK .............................................. 1 ..[...]

  • Page 100

    P A GE 100 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENCLOSURE #1 ASSY . ENCLOSURE #1 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF A UL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 101

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 101 ENCLOSURE #1 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4414000102 BASE ....................................................................... 1 ......... S/N 3744467 AND BELOW 1 C4414000112 BASE ................................................................[...]

  • Page 102

    P A GE 102 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENCLOSURE #2 ASSY . ENCLOSURE #2 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLO WING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 103

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 103 ENCLOSURE #2 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4444000003 REAR FRAME 1 2 3875151004 LOUVER P ANEL 1 3 0205006000 HEX. NUT 2 1 3 0042306000 LOCK W ASHER 2 1 3 0042406000 PLAIN W ASHER 2 1 4 C4444000103 REAR FRAME 1 5 C4444000203 REAR FRAME 1 6 C44440003[...]

  • Page 104

    P A GE 104 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENCLOSURE #2 ASSY . ENCLOSURE #2 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLO WING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 105

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 105 DCA-600SSK — ENCLOSURE #2 ASSY . ENCLOSURE #2 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 3 4 M9110100340 HINGE ....................................................... 2 ......... REPLACES 0845047204 3 4 0845045004 W ASHER 2 3 5 011008020 HEX. HEAD BOL T ........[...]

  • Page 106

    P A GE 106 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — ENCLOSURE #3 ASSY . ENCLOSURE #3 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-GR[...]

  • Page 107

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 107 ENCLOSURE #3 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C4454201603 SPLASHER P ANEL ..................... 1 ....... S/N 3692434 - 3700696 1 C4454201613 SPLASHER P ANEL ..................... 1 ....... S/N 3700696 - 3744467 1 C4454201623 SPLASHER P ANEL ..........[...]

  • Page 108

    P A GE 108 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — R UBBER SEAL ASSY . R UBBER SEAL ASSY .[...]

  • Page 109

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 109 R UBBER SEAL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 0228901640 R UBBER SEAL 6 2 0228900970 R UBBER SEAL 4 3 0228901100 R UBBER SEAL 4 4 0228900990 R UBBER SEAL 2 5 0229201650 R UBBER SEAL 2 6 0228800860 R UBBER SEAL 2 7 0228801380 R UBBER SEAL 2 8 0229200780[...]

  • Page 110

    P A GE 110 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — NAMEPLA TE AND DECALS NAME PLA TE AND DECALS[...]

  • Page 111

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 111 NAME PLA TE AND DECALS NO P AR T NO P AR T NAME QTY . REMARKS CONTROL BO X G R OUP 1 Z0110001204 DECAL: DROOP , Z011000120 1 UP TO S/N 3693908 2 Z0110001304 DECAL: IDLE SPEED ................................................ 1 ........ Z011000130 3 Z0110001504 DECAL: [...]

  • Page 112

    P A GE 112 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) DCA-600SSK — NAMEPLA TE AND DECALS NAME PLA TE AND DECALS[...]

  • Page 113

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 113 DCA-600SSK — NAMEPLA TE AND DECALS NAME PLA TE AND DECALS NO P AR T NO P AR T NAME QTY . REMARKS PROCEDURE GROUP 2 3 C4551001002 DECAL: HANDLING PROCEDURES ........................ 1 ........ C45100100 2 4 8490611303 D EC A L : PRO C EDURES FOR ST AR T UP .........[...]

  • Page 114

    P A GE 114 — DCA-600SSK — OPERA TION AND P ARTS MANU AL (STD) — REV . #7 (04/30/10) Effective: October 1, 2002 TERMS AND CONDITIONS OF SALE — P AR TS P A YMENT TERMS T erms of pa yment f or par ts are net 10 days. FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F .O[...]

  • Page 115

    DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 115 NO TE P A GE[...]

  • Page 116

    Y our Local Dealer is: HERE’S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2010, MUL TIQUIP INC . MQ P ow er and the MQ P ower logo are registered trademarks of Multiquip Inc. and ma y not be used, reproduced, or altered without written permission. All other trademarks are the proper ty of their respe[...]