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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.
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PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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424-9153), 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...
❒ ❒ ❒ ❒ ❒ Applicable Model Number All orders are treated as Standard Orders and will ship the same day if received prior WE ACCEPT ALL MAJOR CREDIT CARDS! DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 5...
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. l a r h / l l u ( . l r h / ( . l r h / ( . l r h / PAGE 6 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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. n i . n i . n i . n i . n i . n i . n i . n i . n i DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 7...
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DANGER - ELECTROCUTION HAZARDS During operation of this generator, there exists the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even DEATH! PAGE 8 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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This generator, other property, or the surrounding environment NOTE could be damaged if you do not follow instructions. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 9...
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■ 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. PAGE 10 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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■ NEVER power cables or cords lay in wate r. ■ NEVER stand in water while AC power from the generator is being transfer to a load. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 11...
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PAGE 12 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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■ DOT Requirements include the following: 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...
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.
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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. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 19...
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Muffler Assembly Fuel Tank Assembly Engine and Radiator Assembly Battery Assembly Generator Assembly Output Terminal Assembly Generator Control Panel Assembly Engine Operating Panel Assembly Figure 5. Major Components DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 21...
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AC Ammeter – Indicates the amount of current the load is drawing from the generator. 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)
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If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the manual position, the generator will start immediately. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 23...
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DCA-600SSV — ENGINE OPERATING PANEL PRE-HEAT BATTERY SWITCH LAMP EMERGENCY WATER TEMP. OIL PRESS. FUEL LEVEL CHARGE AIR FILTER ENGINE SPEED STOP HIGH TACHOMETER PRE-HEAT BUTTON Figure 7. Engine Operating Panels PAGE 24 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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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 AIR FILTER filter. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 25...
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Two 120V GFCI receptacles, 20 amp NOTE are considered bonded grounds . Two (2) GFCI circuit breakers 120V@ 20 amps Eight (16) output terminal lugs Figure 8. Output Terminal Panel PAGE 26 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
(CS-6369) receptacles (Figure 10) provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board position. Figure 10. 240/139 VAC Twist-Lock Auxiliary Receptacles DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 27...
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The entire load connected to the UVWO output terminal lugs, duplex and auxiliary receptacles must not exceed 528 kW in standby or 480 kW in prime output. Figure 12. Connecting Loads PAGE 28 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
W and U terminals as indicated in the AC Voltmeter Gauge (Figure 17). Figure 17 AC Voltmeter Figure 16. AC Voltmeter Gauge Change-Over Switch (Volt reading on W-U Lug) DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 31...
Use voltage regulator adjustment knob whenever fine tuning of the output Figure 24. UVWO Terminal Lugs voltage is required 1Ø-120V Connections PAGE 32 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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NEVER attempt to connect a load to the UVWO output terminals while the generator is operating. The possibility exists of serious injury, electrical shock, electrocution even death. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 33...
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Handle fuel in a safety container. If the container does not ACEA Specification E3 have a spout, use a funnel. Wipe up any spilled fuel ACEA Specification E2 immediately. Figure 30. Double Fuel Tank System PAGE 34 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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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...
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(See Figure 35). Notice how the trailer filler tube level rises when the internal tank is filled. Figure 37. Fuel Expansion Figure 35. Filling Secondary Internal Fuel Tank PAGE 36 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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Tighten all hose clamps and check hoses for leaks. Figure 39. Battery Connections If any hose ( fuel or oil ) lines are defective replace them immediately . PAGE 38 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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Figure 43. Load Connections is lit (ON). 6. Close all engine enclosure doors (Figure 44). Figure 41. Main Circuit Breaker OFF Lamp CORRECT INCORRECT Figure 44. Engine Enclosure Doors DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 39...
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11. Once the engine is warm and the engine is running properly, place the engine speed switch in the “ HIGH ” position (Figure 49). Figure 53. Voltage Adjust Control Knob Figure 49. Engine Speed Switch (High) PAGE 40 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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Figure 60. GFCI and Auxiliary Under normal operating conditions this speed is Circuit Breakers (ON) approximately 1800 RPM’s. Figure 57. Engine Tachometer Gauge DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 41...
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Auto-Start mode. Failing to set the switch in the proper position can result in damage to your generator when it turns on. PAGE 42 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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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...
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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)
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Drain the fuel in the fuel body together with the mixed accumulated inside the fuel tank. water. DO NOT spill the fuel during disassembly. Vent any air Figure 69. Fuel Tank Cleaning DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 45...
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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)
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Figure 71. Battery Charger & Jacket Water Heater Power Connections DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 47...
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Dragging Brakes Bearings of the wheel adjusted? Adjust. The brake controller is not the same as the safety breakaway brake system that may be equipped on the trailer. PAGE 48 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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ALWAYS wear safety glasses when removing or installing force NOTE fitted parts. Failure to comply may result in serious injury. Figure 70. Major Suspension Components DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 49...
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Figure 71. Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts. NOTE Use a torque wrench to tighten lug nuts. PAGE 50 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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Excessive valve clearance? Adjust. Battery discharged? Charge battery. Starter malfunctioning? Repair or replace. Starter does not run. Key switch malfunctioning? Repair or replace. Wiring disconnected? Connect wiring. PAGE 56 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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Repair or replace the injection pump. Deficient nozzle injection? Repair or replace the nozzle. Replace head gasket, tighten cylinder head bolt, glow plug and Compression leak? nozzle holder. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 57...
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Check load and repair. Over current? Confirm load requirements and reduce. Circuit Breaker Tripped 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)
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Engine Controller needs to be calibrated? Refer to dealer. Magnetic pick up out of adjustment? Adjust magnetic pick up. Loss of MPU light(s) or Magnetic pick up dirty? Clean magnetic pick up. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 59...
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Figure 80. Error Code Low Radiator Coolant NOTE Switch is placed in the AUTO position, the same error codes will apply. Codes will not be active until the unit is activated. PAGE 60 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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NOTE PAGE DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 61...
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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)
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1 ....ECU9988N600/800 ..ECU ENGINE CONTROLLER S/N 3698617~ Part number on this Suggested Spare Parts List may super cede/replace the NOTE P/N shown in the text pages of this book. DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 63...
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HEX. HEAD BOLT 0043606000 SPRING WASHER 8461332003 COVER, FAN 0017106050 HEX. HEAD BOLT 0605000012 RUBBER SUSPENSION 0030020000 HEX. NUT 0040020000 SPRING WASHER C3164701404 SPACER, BEARING 0070506208 BEARING DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 67...
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DCA-600SSV — CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 68 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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0601807516 CIRCUIT BREAKER, 1600 AMPS 0015308045 HEX. SOCKET HEAD CAP SCREW 0042508000 SPRING WASHER 0041208000 PLAIN WASHER 0010114055 HEX. HEAD BOLT 0030014000 HEX. NUT 0040014000 SPRING WASHER DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 69...
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DCA-600SSV — CONTROL BOX ASSY. (CONT.) CONTROL BOX ASSY. PAGE 70 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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CIRCUIT BREAKER RESET SWITCH 0601831224 CIRCUIT BREAKER SWITCH C9221100004 HEX. HEAD BOLT 0040008000 SPRING WASHER 0041208000 PLAIN WASHER 0080200007 SNAP RING 3871824004 STOPPER, CONTROL PANEL 0041206000 PLAIN WASHER DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 71 ..
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DCA-600SSV — CONTROL BOX ASSY. (CONT.) CONTROL BOX ASSY. PAGE 72 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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SIDE PANEL, CONTROL BOX 0017108020 HEX. HEAD BOLT C4214400404 PANEL, CONTROL BOX 8481825304 PANEL, CONTROL BOX 0017108020 HEX. HEAD BOLT 0017110030 HEX. HEAD BOLT 0017108020 HEX. HEAD BOLT DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 73...
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DCA-600SSV — ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 74 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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HEX. HEAD BOLT C4374200503 COVER, AIR CLEANER 51-1 0310000520 RUBBER SEAL 0017108020 HEX. HEAD BOLT C3374200104 COVER, AIR CLEANER 0017108020 HEX. HEAD BOLT 0019210025 HEX. HEAD BOLT C4464502504 GUTTER DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 97...
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DOOR HANDLE 0021806015 MACHINE SCREW 0845046904 HINGE 0845045004 WASHER 0845047004 HINGE 0845045004 WASHER 0019208020 HEX. HEAD BOLT 0601850097 STOPPER 0025408025 MACHINE SCREW 0019208070 HEX. HEAD BOLT 0845031504 DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 99...
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DCA-600SSV — RUBBER SEAL ASSY. RUBBER SEAL ASSY. PAGE 100 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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0228800860 RUBBER SEAL 0228801380 RUBBER SEAL 0229201490 RUBBER SEAL 0229200780 RUBBER SEAL 0229200595 RUBBER SEAL 0228100500 RUBBER SEAL 0228100270 RUBBER SEAL 0228100580 RUBBER SEAL 0228100140 RUBBER SEAL DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 101...
Rebates for price declines and added charges Multiquip’s designated receiving point. for price increases will not be made for stock on hand at the time of any price change. PAGE 106 — DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09)
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NOTE PAGE DCA-600SSV — OPERATION AND PARTS MANUAL — REV. #0 (07/13/09) — PAGE 107...