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Multiquip DCA-800SSK operation manual Diesel engine exhaust and some of

Models: DCA-800SSK

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Diesel engine exhaust and some of

PAGE 2 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

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Multiquip DCA-800SSK operation manual Diesel engine exhaust and some of

Contents

MODEL DCA-800SSK OPERATION AND PARTS MANUALSTANDARD PORTABLE GENERATORDiesel engine exhaust and some of DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE COMPONENT DRAWINGS MQ Power DCA-600SSK AC GeneratorDCA-800SSKTABLE OF CONTENTS 72-75Choose from three easy options PARTS ORDERING PROCEDURESWhen ordering parts, please supply OrderGenerator Specifications DCA-800SSK - SPECIFICATIONSEngine Specifications NOTE PAGE DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEDCA-800SSK - DIMENSIONS TOP AND SIDE Figure 1. DimensionsDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK- DIMENSIONS FRONT , REAR AND DOORSFigure 2. Dimensions SAFETY MESSAGE ALERT SYMBOLS DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS Whisperwatt GeneratorCAUTION - ACCIDENTAL STARTING DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - OVER-SPEED CONDITIONSDANGER - READTHIS MANUAL General SafetyDCA-800SSK - RULES FOR SAFE OPERATION GeneratorGenerator Grounding Electrical SafetyDCA-800SSK - RULES FOR SAFE OPERATION DANGER - ELECTROCUTION HAZARDSDANGER - EXPLOSION HAZARDS Maintenance SafetyBattery Safety DCA-800SSK - RULES FOR SAFE OPERATIONDCA-800SSK - RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies ALWAYS know the location of the nearest fire extinguisherDCA-800SSK - INSTALLATION Figure 3. Typical Generator Grounding ApplicationCAUTION - EXHAUST HAZARD DCA-800SSK - INSTALLATIONOutdoor Installation MountingCAUTION -TOWING REGULATIONS Towing Safety PrecautionsDCA-800SSK -TOWING RULES FOR SAFE OPERATION Figure 4. Generator and TrailerCAUTION -TRAILER INSPECTION DCA-800SSK -TRAILER-SAFETY GUIDELINESExplanation of Chart MODEL DCA-800SSK -TRAILER-SPECIFICATIONSTable 3. Trailer Specifications FUEL CELLDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK -TRAILER-SPECIFICATIONSTable 3. Specifications Cont MODELDCA-800SSK - OPERATION AND SAFETY DECALS Machine Safety DecalsDCA-800SSK - OPERATION AND SAFETY DECALS DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEDCA-800SSK - OPERATION AND SAFETY DECALS DCA-800SSK - OPERATION AND SAFETY DECALS DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEDCA-600SSK FAMILIARIZATION Generator Microprocessor Controlled Alarm SystemDCA-800SSK - GENERAL INFORMATION Engine Control PanelDESCRIPTION DCA-800SSK - MAJOR COMPONENTSTable 4. Generator Major Components DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEDCA-800SSK - GENERATOR CONTROL PANEL Up to S/N S/N 3699248~ Figure 6. Generator Control PanelDCA-800SSK - GENERATOR CONTROL PANEL DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEDCA-800SSK - ENGINE OPERATING PANEL Up to S/N S/N 3699248~ Figure 7. Engine Operating PanelsDCA-800SSK - ENGINE OPERATING PANEL DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEThe “Output Terminal Panel ” Figure 8 is provided with the following DCA-800SSK - OUTPUTTERMINAL OVERVIEWOutput Terminal Familiarization Output Terminal PanelFigure 9. G.F.C.I. Receptacle DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW120VAC GFCI Receptacles Figure 11. Voltage Regulator Control KnobDCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW Connecting LoadsMaximum Power Output KW Over Current RelayThree Phase Load Single Phase LoadTable 13. Power Factor By Load DCA-800SSK- LOAD APPLICATIONVoltage Change-Over Board DCA-800SSK - GENERATOR OUTPUTSGenerator OutputVoltages Generator AmperageMaximum Amps How to Read the OutputTerminal GaugeDCA-800SSK - GENERATOR OUTPUTS/GAUGE READING Figure 19. AC Ammeter Change-Over Switch3Ø-240V UVWO Terminal Output Voltages DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages1Ø-480V UVWO Terminal Output Voltages DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-480V UVWO Terminal Output Voltages 1Ø-277V UVWO Terminal Output VoltagesLubrication Oil DCA-800SSK - PRE-SETUPCircuit Breakers Fuel CheckWARNING - RESPIRATORY HAZARDS Refilling ProceduresCAUTION -TRAILER FUELTANK refuelingFigure 35. Full Trailer Tank CAUTION - REFUELING SECONDARY FUELTANKDCA-800SSK - PRE-SETUP Figure 37. Full Fuel SystemAir Cleaner DCA-800SSK- PRE-SETUPCleaning the Radiator Operation Freezing WeatherCAUTION - BATTERY SERVICING SAFETY BatteryBattery Cable Installation WiringCAUTION - LETHAL EXHAUST HAZARD DCA-800SSK - GEN. START-UP PROCEDURE MANUALBefore Starting Generator and Control PanelFigure 45. Battery ON/OFF Switch DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL5. Set the battery ON/OFF switch Figure 45 to the “ON” position Figure 46. Ignition Switch Pre-HeatFigure 47. Oil Pressure Gauge DCA-800SSK - GENERATOR START-UP PROCEDURE MANUALFigure 48. Coolant Temperature Gauge Figure 50. Main, Aux. and GFCI Circuit Breakers ONDCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL 20. Set the battery ON/OFF switch Figure 60 to the “ON” positionBEFORE STARTING Generator and Control Panel Figure 62. Engine Speed Switch HighWARNING - AUTO MODE MAINTENANCE DCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTOCAUTION - BACKUP GENERATOR USE 2. Set the battery ON/OFF switch Figure 66 to the “ON” positionWARNING - EMERGENCY STOP SWITCH DCA-600SSK - GENERATOR SHUT-DOWN PROCEDUREEmergency Shutdown Procedure Engine Shutdown Controller S/N 3698617~10 Hrs DCA-800SSK - MAINTENANCEINSPECTION / MAINTENANCE 250 HrsGeneral Inspection Service DailyCleaning the Fuel Strainer Outer ElementReplacing Fuel Filter Flushing Out Radiator and Changing CoolantChanging Oil DCA-800SSK - MAINTENANCEGenerator Storage Cleaning Breather ElementGreasing Removal From Long Term StorageFigure 75. Battery Charger/Jacket Water Heater Power Connections DCA-800SSK - MAINTENANCENOTEapplied to the generators internal battery charger DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGES-Cam Brakes BrakesAir Brake System Brake Drums or discs, Linings, and HosesCAUTION - EYESIGHT HAZARD DCA-800SSK -TRAILER MAINTENANCETires/Wheels/Lug Nuts Tire Wear/InflationFigure 78. Wheel Lug Nuts Tightening Sequence DCA-800SSK -TRAILER MAINTENANCELug NutTorque Requirements Table 18. Tire Torque RequirementsDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK -TRAILER-WIRING DIAGRAMFigure 79. Trailer Wiring Diagram 5-Pin DCA-800SSK -TRAILER-WIRING DIAGRAM Figure 80. Trailer Wiring Diagram 7-PinDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - GENERATOR WIRING DIAGRAMFigure 81. Generator Wiring Diagram DCA-800SSK - GENERATOR WIRING DIAGRAM MAIN BREAKER Figure 82. Main Circuit Breaker Wiring DiagramDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - ENGINE WIRING DIAGRAMFigure 83. Engine Wiring Diagram DCA-800SSK - ENGINE WIRING DIAGRAM Figure 84. Engine Wiring DiagramContinuedDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAMFigure 85. Electronic Governor Controller SYMPTOM DCA-600SSK -TROUBLESHOOTING ENGINETABLE 20. ENGINE TROUBLESHOOTING POSSIBLE PROBLEMSYMPTOM DCA-800SSK -TROUBLESHOOTING ENGINETABLE 20. ENGINE TROUBLESHOOTING CONTINUED POSSIBLE PROBLEMSYMPTOM DCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINETABLE 21. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMSolution DCA-800SSK -TROUBLESHOOTING MPECTABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC SymptonQTY. Column EXPLANATION OF CODE IN REMARKS COLUMNSAMPLE PARTS LIST NO. ColumnDCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units DCA-800SSK - SUGGESTED SPARE PARTSDescription DCA-800SSK - GENERATOR ASSY GENERATOR ASSYDCA-800SSK - GENERATOR ASSY PART NAMEQTY. REMARKS DCA-800SSK - GENERATOR ASSY QTY. REMARKS DCA-800SSK - GENERATOR ASSYPART NAME DCA-800SSK - CONTROL PANEL ASSY CONTROL PANEL ASSYPART NAME DCA-800SSK - CONTROL PANEL ASSYREMARKS S/N 3699248~ REPLACESDCA-800SSK - CONTROL BOX ASSY CONTROL BOX ASSYREMARKS DCA-800SSK - CONTROL BOX ASSYPART NAME S/N 3692434 TO S/NDCA-800SSK - CONTROL BOX ASSY REMARKS DCA-800SSK - CONTROL BOX ASSYPART NAME CHANGE-OVER BOARD, VOLTAGEDCA-800SSK - ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYREMARKS DCA-800SSK - ENGINE AND RADIATOR ASSYPART NAME DCA-800SSK - ENGINE AND RADIATOR ASSY REMARKS DCA-800SSK - ENGINE AND RADIATOR ASSYPART NAME DCA-800SSK - OIL DRAIN ASSY OIL DRAIN ASSYPART NAME DCA-800SSK - OIL DRAIN ASSYDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE REMARKSDCA-800SSK - ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSYDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - ENGINE OPERATING PANEL ASSYENGINE OPERATING PANEL ASSY DCA-800SSK - OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYBRACKET, OUTPUT TERMINAL DCA-800SSK - OUTPUTTERMINAL ASSYPART NAME SET BOARD, OUTPUT TERMINALDCA-800SSK - OUTPUTTERMINAL ASSY REMARKS DCA-800SSK - OUTPUTTERMINAL ASSYPART NAME C4237100504DCA-800SSK - BATTERY ASSY BATTERY ASSYDCA-800SSK - BATTERY ASSY PART NAMEDCA-800SSK - MUFFLER ASSY MUFFLER ASSYDCA-800SSK - MUFFLER ASSY PART NAMEDCA-800SSK - FUELTANK ASSY FUEL TANK ASSYREMARKS DCA-800SSK - FUELTANK ASSYPART NAME CAP, FUEL TANKOF ORANGE. TO ORDER WITH DIFFERENT COLOR DCA-800SSK - ENCLOSURE #1 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYENCLOSURE #1 ASSY DCA-800SSK - ENCLOSURE #1 ASSYPART NAME OF ORANGE. TO ORDER WITH DIFFERENT COLOR THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #1 ASSY PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYREMARKS DCA-800SSK - ENCLOSURE #1 ASSYPART NAME OF ORANGE. TO ORDER WITH DIFFERENT COLOR DCA-800SSK - ENCLOSURE #2 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYENCLOSURE #2 ASSY DCA-800SSK - ENCLOSURE #2 ASSYPART NAME OF ORANGE. TO ORDER WITH DIFFERENT COLOR THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #2 ASSY PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYREMARKS DCA-800SSK - ENCLOSURE #2 ASSYPART NAME OF ORANGE. TO ORDER WITH DIFFERENT COLOR DCA-800SSK - ENCLOSURE #3 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYQTY. REMARKS DCA-800SSK - ENCLOSURE #3 ASSYPART NAME ENCLOSURE #3 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #3 ASSY PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #3 ASSY PART NAMEDCA-800SSK - RUBBER SEALS ASSY RUBBER SEALS ASSYRUBBER SEALS ASSY DCA-800SSK - RUBBER SEALS ASSYPART NAME DCA-800SSK - NAME PLATE AND DECALS NAME PLATE AND DECALSDCA-800SSK - NAME PLATE AND DECALS PROCEDURE GROUPCONTROL PANEL GROUP PART NAMEDCA-800SSK - NAME PLATE AND DECALS ENGINE & RADIATOR GROUP BATTERY GROUPDCA-800SSK - NAME PLATE AND DECALS OIL DRAIN GROUPPAYMENT TERMS TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE FREIGHT POLICYNOTE PAGE DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEMQ Power HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Contact mqpower@multiquip.com