MQ Power WHISPERWATT DCA600SSV4F3 User manual

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
WHISPERWATT™ SERIES
MODEL DCA600SSV4F3
60HZ GENERATOR
(VOLVO PENTA TWD1672GE DIESEL ENGINE)
INSTRUCTION MANUAL NO. C4844304614
Revision #2 (11/15/22)
OPERATION MANUAL
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com

PAGE 2 — DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22)
PROPOSITION 65 WARNING

DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22) — PAGE 3
TABLE OF CONTENTS
DCA600SSV4F3
60 Hz Generator
Proposition 65 Warning ........................................... 2
Table of Contents..................................................... 3
Safety Decals .......................................................... 4
Safety Information ............................................. 5–10
Specifications ........................................................ 11
Dimensions............................................................ 12
Installation ....................................................... 13–14
General Information............................................... 15
General Paralleling Information (Option) ......... 16–18
Major Components ................................................ 19
Engine Control Unit (ECU-845) ............................. 20
Gauge Unit Assembly............................................ 21
Control and Operation Panel ........................... 22–23
Basler Digital Genset Controller (Option) ........ 24–25
Paralleling Panel (Option)................................ 26–27
Output Terminal Panel Familiarization ............. 28–29
Load Application.................................................... 30
PowerBalance™ .................................................... 31
Generator Outputs................................................. 32
Gauge Reading ..................................................... 33
Output Terminal Panel Connections ................ 34–35
Inspection/Setup.............................................. 36–42
Generator Startup Procedure (Manual)........... 43–45
Generator Startup Procedure (Auto Mode) ........... 46
Generator Shutdown Procedures.................... 47–48
Maintenance.................................................... 49–62
Troubleshooting (Diagnostics) ............................... 63
Troubleshooting (Generator).................................. 64
Troubleshooting (Engine)................................. 65–66
Generator Wiring Diagram (C4814005103A) ........ 67
Engine Wiring Diagram (C4814106813)................ 68
MCB Sequence Diagram (C4814209104)............. 69
Engine Block Heater Wiring Diagram (Option) ...... 70
Battery Charger Wiring Diagram (Option) ............. 71
NOTICE
Specifications are subject to change without notice.

PAGE 4 — DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22)
SAFETY DECALS
SAFETY DECALS
Safety decals are attached to the generator as shown in
Figure 1. Keep these safety decals clean at all times.When
the safety decals become worn or damaged, contact your
nearest dealer or the Multiquip Parts Department.
NOTICE
For safety decal part numbers, refer to the associated
parts manual.
Figure 1. Safety Decals
B90400040
WARNING
MOVING PARTS can cause
severe injury.
DO NOT operate with doors
open.
Stop engine before servicing.
AN SHROUDF
WARNING
DIESEL FUEL can cause
fire or explosion.
Stop engine before fueling.
B90450000
Keep cigarettes, sparks
and flame away.
EXHAUST FLUID ONLY
Filling this tank with
anything other than
DIESEL EXHAUST FLUID
may result in severe
engine damage.
M94110000
No Diesel
D
CAUTION
REAR VIEW
CONTROL PANEL
TOP VIEW
FRONT VIEW
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
120
V
OFF
GAC-2.2H
POWEREDby
HondaEngines
120V
15A
GRPRISEDE
TERRE
ACCIRCUITBREAKER
INTERRUPTEURDE
COURANTPRINCIPAL
NEUTRALBONDEDTOFRAME
NEUTREMISALAMASSEA
LACARCASSEDUMOTEUR
211052
120
V
OFF
GAC-2.2H
POWEREDby
HondaEngines
120V
15A
GRPRISEDE
TERRE
ACCIRCUITBREAKER
INTERRUPTEURDE
COURANTPRINCIPAL
NEUTRALBONDEDTOFRAME
NEUTREMISALAMASSEA
LACARCASSEDUMOTEUR
211052
120
V
OFF
GAC-2.2H
POWEREDby
HondaEngines
120V
15A
GRPRISEDE
TERRE
ACCIRCUITBREAKER
INTERRUPTEURDE
COURANTPRINCIPAL
NEUTRALBONDEDTOFRAME
NEUTREMISALAMASSEA
LACARCASSEDUMOTEUR
211052
NEVER use inside a home
or garage. Even if doors
and windows are open.
ONLY use OUTSIDE and
far away from windows,
doors, and vents.
Generator exhaust contains carbon monoxide. This is
a poison gas you cannot see or smell.
Avoid other generator hazards.
READ MANUAL BEFORE USE.
A90400001
B90420000
WARNING
ENGINE EXHAUST can cause
severe injury or death.
Use only in open, well
ventilated areas or
vent exhaust outside.
Diesel engine exhaust and some of
Operation of this equipment may create
sparks that can start fires around dry
vegetation.
A spark arrestor may be required.
The operator should contact local fire
agencies for laws or regulations
relating to fire prevention requirements.
M90420000
M92010070
WARNING
ARC FLASH AND SHOCK HAZARD
Appropriate PPE Required
Appropriate Personal Protection
Equipment and Tools Required
when working on this equipment.
B93110060
WARNING
ELECTRIC SHOCK HAZARD
Do not touch internal wiring
or connections while this
machine is operating.
Turn power off before
servicing.
This machine stops and starts automatically
and without notice.
CAUTION
C92210000
B90410010
WARNING
HOT COOLANT can cause
severe burns.
Do not remove cap if
radiator is hot.
Ensure the “Auto-Off/Reset-Manual” switch is
in the “Off/Reset” position. If it is not, when
the battery cables are connected, the engine
will crank and attempt to start.
CAUTION
C90530000
B93110060
WARNING
ELECTRIC SHOCK HAZARD
Do not touch internal wiring
or connections while this
machine is operating.
Turn power off before
servicing. B90400030
CAUTION
HOT PARTS can burn skin.
DO NOT get on the roof
until the machine is
cooled sufficiently.
WARNING
ELECTRIC SHOCK HAZARD
Do not touch output
terminals while this
machine is operating.
Turn power off before
servicing.
B93110050
WARNING
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch.
B91110030
Serious injury or death may result without this
transfer switch.
WARNING
ELECTRIC SHOCK HAZARD
Always complete the grounding
path from the ground terminal
on the genset to an external
grounding source.
See instruction manual for
details. B91110040
CAUTION
C90420050
During urea SCR system purging, the smell of
ammonia may emanate from the tailpipe temporarily.
Do not operate the machine in a place with poor
ventilation.
If you begin to feel sick, stop the engine
immediately and ventilate the area.
SAFETY INSTRUCTIONS
Improper operation of this machine can cause
severe injury or death.
Read the instruction manual carefully
before operation or servicing.
This machine should only be operated by a
person with sufficient knowledge and skill
to ensure safe operation.
High voltage circuits are located inside the
output terminal cover and control panel.
Close the cover and control panel before
operating.
Moving parts and hot surfaces are contained
within the enclosure.
Close all doors and lock them before
operating. C25100000
CAUTION
Maximum Capacity of lifting
bail is 25,000 lbs.
C90400040
SIDE VIEW SIDE VIEW

DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22) — PAGE 5
SAFETY INFORMATION
Do not operate or service the generator before reading the
entire manual. Safety precautions should be followed at all
times when operating this generator. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
SAFETY MESSAGES
The four 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 four words:
DANGER, WARNING, CAUTION
or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
Potential hazards associated with the operation of this
generator will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.

PAGE 6 — DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION

NEVER operate this generator without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.

NEVER operate this generator when not
feeling well due to fatigue or illness, or when
on medication.

NEVER operate this generator under the influence of
drugs or alcohol.

ALWAYS check the generator for loosened threads or
bolts before starting.

NEVER use the generator for any purpose other than
its intended purposes or applications.
NOTICE

This generator should only be operated by trained and
qualified personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and
safety decals when they become difficult to read.

Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
modification of the generator will void all warranties.

NEVER use accessories or attachments that are not
recommended by MQ Power for this generator. Damage
to the generator and/or injury to the user may result.

ALWAYS know the location of the nearest
fire extinguisher.

ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest phone or keep
a phone on the job site.
Also, know the phone numbers
of the nearest ambulance, doctor, and
fire department.
This information will be invaluable in the case of an
emergency.
GENERATOR SAFETY
DANGER
NEVER operate the generator in an
explosive atmosphere or near combustible
materials. An explosion or fire could result
causing severe bodily harm or even death.
WARNING
NEVER disconnect any emergency or safety devices
.
These devices are intended for operator safety.
Disconnection of these devices can cause
severe injury,
bodily harm or even death
. Disconnection of any of
these devices will void all warranties.
CAUTION
NEVER
lubricate components or attempt service on a
running generator.
NOTICE
ALWAYS
ensure the generator is on level ground
before use.
ALWAYS
keep the generator in proper running condition.

Fix damage to the generator and replace any broken
parts immediately.
ALWAYS
store the generator properly when it is not
being used. The generator should be stored in a clean,
dry location out of the reach of children and unauthorized
personnel.

DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER

The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.

The engine of this generator
requires an adequate, free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.

When operating the generator outdoors, DO NOT place
the generator near doors, windows or vents that could
allow carbon monoxide to enter and build up in occupied
spaces.
WARNING

NEVER place hands or fingers inside the engine
compartment when the engine is running.

NEVER operate the engine with heat shields or
guards removed.

Keep fingers, hands, hair and clothing away
from all moving parts to prevent injury.

NEVER operate the generator with the
doors open. Stop the engine before servicing.

DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.

DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.

DO NOT drain the engine oil while the engine is hot. Hot
oil will gush out and severely scald any persons near
the generator.
Operation of the generator may create sparks that
can start fires around dry vegetation. A spark arrestor
may be required. The operator should contact local fire
agencies for laws or regulations relating to fire prevention
requirements.
CAUTION
NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing the generator.
NOTICE
NEVER
run the engine without an air filter or with a dirty
air filter. Severe engine damage may occur. Service the
air filter frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or generator can result if
operating in speed ranges above the
maximum allowable.

Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
sufficient load (less than 30-35% of the rated output),
it will not operate at its optimum temperature. This will
allow unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.

PAGE 8 — DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22)
SAFETY INFORMATION
FUEL SAFETY
DANGER

NEVER start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.

ALWAYS use extreme caution when working with
flammable liquids.

NEVER fill the fuel tank while the engine is
running or hot.

NEVER overfill the fuel tank. Spilled fuel can ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.

Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

NEVER smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION

Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
SafetyTowing Regulations,before towing
your generator.

Refer to the MQ Power trailer manual for additional safety
information.

In order to reduce the possibility of an accident
while transporting the generator on public roads,
ALWAYS make sure that the trailer that supports the
generator and the towing vehicle are both mechanically
sound and in good operating condition.

ALWAYS shut down the engine before transporting.
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.

Check the tire air pressure on both the towing vehicle and
the trailer.
Inflate trailer tires as indicated on side wall
of tire.
Also check the tire tread wear on both vehicles.
ALWAYS
make sure the trailer is equipped with
safety chains.
ALWAYS properly
attach the trailer’s safety chains to
the towing vehicle.
ALWAYS
make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
DOT requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with
tie wraps.
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 the type
of terrain.

Avoid sudden stops and starts.These can cause skidding
or jackknifing. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.

The trailer should be adjusted to a level position at all
times when towing.

Raise and lock the trailer wheel stand in the upright
position when towing.
Place chock blocks
underneath the wheels to prevent
rolling while parked.
Place support blocks
underneath the trailer’s bumper
to prevent tipping while parked.

Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.

DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER

NEVER touch the output terminals
during operation. Contact with the
output terminals during operation can
cause electrocution, electrical shock,
or burn.

The electrical voltage required to
operate the generator can cause severe injury or even
death through physical contact with live circuits.Turn the
generator and all circuit breakers OFF before performing
maintenance on the generator or making contact with
the output terminals.

NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous.The possibility exists
of electrical shock,electrocution or death.

Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance
with all applicable laws and electrical codes. Failure to
do so could result in electrical shock or burn, causing
serious injury or even death.
Power Cord/Cable Safety
DANGER

NEVER let power cords or cables lay in water.

NEVER stand in water while AC power from the
generator is being transferred to a load.

NEVER use damaged or worn cables or cords when
connecting equipment to the generator. Inspect the
insulation for cuts.

NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the generator.
NOTICE
ALWAYS
make certain that the proper power or
extension cord has been selected for the job. See the
Cable Selection Chart in this manual.
Grounding Safety
DANGER
ALWAYS
make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating the generator.
Severe injury or
death by electrocution
can result from operating an
ungrounded generator.
NEVER use gas piping as an electrical ground.
BATTERY SAFETY
DANGER
DO NOT
drop the battery. There is a possibility that the
battery will explode.
NEVER expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS
keep the battery charged. If the battery is not
charged, combustible gas will build up.
ALWAYS
recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gases.

If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin
, rinse skin or clothing
immediately with plenty of water.

PAGE 10 — DCA600SSV4F3 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (11/15/22)
SAFETY INFORMATION
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION

ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.

ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
ENVIRONMENTAL SAFETY/DECOMMISSIONING
NOTICE
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement), be
sure to follow the rules below:

NEVER pour waste or oil directly onto the ground, down
a drain, or into any water source.

Contact your country’s Department of Public
Works or recycling agency in your area and
arrange for proper disposal of any electrical
components, waste or oil associated with
this equipment.

When the life cycle of this equipment is over, remove
the battery and bring it to an appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.

When the life cycle of this equipment is over, it is
recommended that the frame and all other metal parts
be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
EMISSIONS INFORMATION
NOTICE
The diesel engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC), and nitrogen oxides (NOx)
contained in diesel exhaust emissions.
This engine has been certified to meet US EPA evaporative
emissions requirements in the installed configuration.
Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe
condition.
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fines or other penalties.
Emission Control Label
The emission control label is an integral part of the emission
system and is strictly controlled by regulations.
The label must remain with the engine for its entire life.
If a replacement emission label is needed, please contact
your authorized engine distributor.