Multiquip 60 Hz Generator DCA-400SSV User Manual

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUALRevision #0 (04/19/06)THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALL TIMES.WHISPERWATTTM SERIESMOD

PAGE 10 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— RULES FOR SAFE OPERATIONThe following safety guidelines should alw

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 111DCA-400SSV— RULES FOR SAFE OPERATIONPOWERCORD(POWER ON)WETHANDSDuring operation

PAGE 12 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— RULES FOR SAFE OPERATIONBattery SafetyUse the following guidelines

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 131Emergencies ALWAYS know the location of thenearest fire extinguisher. ALWAYS

PAGE 14 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)The DCA-400SSVgenerator is equipped with a number of safety decals (Figures 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 151DCA-400SSV— GENERATOR DECALSFigure 3. Generator Decals (Cont inued)

PAGE 16 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Figure 4. Typical Generator Grounding ApplicationDCA-400SSV— INSTALLATION

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 171Outdoor InstallationInstall the generator in a area that is free of debris,byst

PAGE 18 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— GENERAL INFORMATIONDCA-400SSVWhisperwatt™ Series FamiliarizationGe

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 191DCA-400SSV— MAJOR COMPONENTSFigure 5. Major Components4elbaT. stnenopmoCrojaMro

PAGE 2 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

PAGE 20 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Figure 6. Generator Control Panel8. Panel Light Switch – When activated will t

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 211DCA-400SSV— GENERATOR CONTROL PANELAlso the engine controller will shut down th

PAGE 22 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Figure 7. Engine Operating PanelDCA-400SSV— ENGINE OPERATING PANELThe definit

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 231NOTE PAGE

PAGE 24 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Output Terminal FamiliarizationThe “Output Terminal Panel ” (Figure 8) is pro

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 251120 VAC GFCI ReceptaclesThere are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R)

PAGE 26 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Figure 12. Connecting LoadsConnecting LoadsLoads can be connected to the gene

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 271DCA-400SSV— LOAD APPLICATIONSingle Phase LoadAlways be sure to check the namepl

PAGE 28 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV — GENERATOR OUTPUTSGenerator AmperageTables 8 and 9 describe the ge

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 291Maximum AmpsTable 10 shows the maximum amps the generator can pro-vide. DO NOT

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 31© COPYRIGHT 2006, MULTIQUIP INC.MQ Power Inc, Ultra-Silent series, and the MQ Po

PAGE 30 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Figure 20. Voltage Change-Over Board 240V ConfigurationUVWO

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 311DCA-400SSV— OUTPUT TERMINAL PANEL CONNECTIONS2. Connect the load wires to the

PAGE 32 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— PRE-SETUPFigure 29. Engine Oil DipstickWhen checking the engine oi

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 331DCA-400SSV— PRE-SETUPRefueling Procedure:1. Level Tanks – Make sure fuel cells

PAGE 34 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Coolant (Antifreeze/Summer Coolant/Water)VOLVO recommends VOLVO antifreeze/sum

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 351DCA-400SSV— PRE-SETUPWhen connecting battery do the following:1. NEVER connect

PAGE 36 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)5. Verify that the Engine Runningstatus LED on the MPEC unit(Figure 43) is ON

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 371DCA-400SSV— GENERATOR START-UP PROCEDURE (MANUAL)Figure 46. Voltage Adjust Cont

PAGE 38 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)1. Perform steps 1 through 5 in the Before Starting sectionas outlined in the

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 391Normal Shutdown ProcedureTo shutdown the generator use the following procedure:

PAGE 4 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)TABLE OF CONTENTSSpecification and partnumber are subject tochange without noti

PAGE 40 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— MAINTENANCEGeneral InspectionPrior to each use, the generator shou

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 411Service DailyIf the engine is operating in very dusty or dry grassconditions, a

PAGE 42 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— MAINTENANCEGenerator StorageFor longe term storage of the generato

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 431DCA-400SSV— MAINTENANCETo ensure adequate startingcapability, always have power

PAGE 44 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— TRAILER MAINTENANCE7. Coupler - Type of hitch used on the trailer

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 451DCA-400SSV— TRAILER MAINTENANCEHydraulic Surge BrakesHydraulic surge brakes (Fi

PAGE 46 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Tires/Wheels/Lug NutsTires and wheels are a very important and criticalcompone

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 471NEVER use an pneumatic airgun to tighten wheel lug nuts.Figure 64. Wheel Lug N

PAGE 48 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— TRAILER WIRING DIAGRAMFigure 65. Trailer/Towing Vehicle Wiring Di

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 491DCA-400SSV— GENERATOR WIRING DIAGRAMFigure 66. Generator Wiring Diagram

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 51MQPOWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-537-3

PAGE 50 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV — ENGINE WIRING DIAGRAM (S/N 3722759 AND BELOW)Figure 67. Engine Wi

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 511Figure 68. Engine Wiring Diagram (S/N 3722760 AND ABOVE)DCA-400SSV — ENGINE WIR

PAGE 52 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)Practically all breakdowns can be prevented by proper handling and maintenance

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 531DCA-400SSV— TROUBLESHOOTING (ENGINE CONTROLLER)Practically all breakdowns can b

PAGE 54 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— TROUBLESHOOTING (DIAGNOSTIC LAMP)The engine controller of this ge

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 551NOTE PAGE

PAGE 56 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— EXPLANATION OF CODE IN REMARKS COLUMNNOTEWhen ordering a part that

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 571DCA-400SSV— SUGGESTED SPARE PARTSDCA-400SSVWHISPER WATTGENRATORW/VOLVO PENTA TA

PAGE 58 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— GENERATOR ASSY.GENERATOR ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 591DCA-400SSV— GENERATOR ASSY.GENERATOR ASSY.NO. PART NO. PART NAME QTY. REMARKS

PAGE 6 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— SPECIFICATIONSsnoitacificepSrotareneG.1elbaTledoMVSS004-ACDepyT,det

PAGE 60 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)GENERATOR ASSY. (CONT.)DCA-400SSV— GENERATOR ASSY. (CONT.)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 611DCA-400SSV— GENERATOR ASSY. (CONT.)GENERATOR ASSY.NO. PART NO. PART NAME QTY.

PAGE 62 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENGINE OPERATING PANEL ASSY.ENGINE OPERATING PANEL ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 631DCA-400SSV— ENGINE OPERATING PANEL ASSY.ENGINE OPERATING PANEL ASSY.NO. PART N

PAGE 64 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— CONTROL BOX ASSY.CONTROL BOX ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 651DCA-400SSV— CONTROL BOX ASSY.CONTROL BOX ASSY.NO. PART NO. PART NAME QTY. REM

PAGE 66 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)CONTROL BOX ASSY. (CONT.)DCA-400SSV— CONTROL BOX ASSY. (CONT)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 671DCA-400SSV— CONTROL BOX ASSY. (CONT)CONTROL BOX ASSY.NO. PART NO. PART NAME Q

PAGE 68 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 691DCA-400SSV— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.NO. PART NO. PA

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 71DCA-400SSV— DIMENSIONS (TOP, SIDE AND FRONT)Figure 1. DimensionsSNOISNEMID.3ELBA

PAGE 70 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 711DCA-400SSV— ENGINE AND RADIATOR ASSY.ENGINE AND RADIATOR ASSY.NO. PART NO. PAR

PAGE 72 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— OUTPUT TERMINAL ASSY.OUTPUT TERMINAL ASSY.THE SERIAL NUMBER MAY BE

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 731DCA-400SSV— OUTPUT TERMINAL ASSY.OUTPUT TERMINAL ASSY.NO. PART NO. PART NAME Q

PAGE 74 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— BATTERY ASSY.BATTERY ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 751DCA-400SSV— BATTERY ASSY.BATTERY ASSY.NO. PART NO. PART NAME QTY. REMARKS1 016

PAGE 76 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— MUFFLER ASSY.MUFFLER ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 771DCA-400SSV— MUFFLER ASSY.MUFFLER ASSY.NO. PART NO. PART NAME QTY. REMARKS1 C33

PAGE 78 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— FUEL TANK ASSY.FUEL TANK ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 791DCA-400SSV— FUEL TANK ASSY.FUEL TANK ASSY.NO. PART NO. PART NAME QTY. REMARKS1

PAGE 8 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)This Owner's Manual has beendeveloped to provide completeinstructions for

PAGE 80 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENCLOSURE #1 ASSY.ENCLOSURE #1 ASSY.THE SERIAL NUMBER MAY BE REQU

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 811DCA-400SSV— ENCLOSURE #1 ASSY.ENCLOSURE #1 ASSY.NO. PART NO. PART NAME QTY. REM

PAGE 82 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENCLOSURE #2 ASSY.ENCLOSURE #1 ASSY.THE SERIAL NUMBER MAY BE REQU

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 831ENCLOSURE #1 ASSY.NO. PART NO. PART NAME QTY. REMARKS1 C3444002203 REAR FRAME 1

PAGE 84 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENCLOSURE #2 ASSY. (CONT.)ENCLOSURE #2 ASSY. (CONT.)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 851ENCLOSURE #2 ASSY. (CONT.)NO. PART NO. PART NAME QTY. REMARKS26 0845050704 STAY

PAGE 86 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENCLOSURE #3 ASSY.ENCLOSURE #3 ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 871ENCLOSURE #3 ASSY.NO. PART NO. PART NAME QTY. REMARKS1 C3454202902 SPLASHER PAN

PAGE 88 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— ENCLOSURE #3 ASSY. (CONT)ENCLOSURE #2 ASSY. (CONT.)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 891ENCLOSURE #2 ASSY. (CONT.)NO. PART NO. PART NAME QTY. REMARKS16 8195151004 LOUV

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 91DCA-400SSV— SAFETY MESSAGE ALERT SYMBOLSALWAYS place the Engine ON/OFFswitch in

PAGE 90 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— RUBBER SEALS ASSY.RUBBER SEALS ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 911DCA-400SSV— RUBBER SEALS ASSY.RUBBER SEALS ASSY.NO. PART NO. PART NAME QTY. REM

PAGE 92 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)DCA-400SSV— NAMEPLATE AND DECALS ASSY.NAMEPLATE AND DECALS ASSY.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 931DCA-400SSV— NAMEPLATE AND DECALS ASSY.NAME PLATE ASSY.NO. PART NO. PART NAME QT

PAGE 94 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 951NAME PLATE AND DECALS ASSY.NO. PART NO. PART NAME QTY. REMARKS5-4 B9511100304 D

PAGE 96 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)TERMS AND CONDITIONS OF SALE — PARTSPAYMENT TERMSTerms of payment for parts ar

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 971NOTE PAGE

PARTS AND OPERATION MANUALOPERATION AND PARTS MANUALYour Local Dealer is:MQ POWERA Division of Multiquip Inc.POST OFFICE BOX 6254CARSON, CA 90749310-5