Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE

Models: DCA-800SSK

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DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 3

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Multiquip operation manual DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE

Contents

PORTABLE GENERATOR OPERATION AND PARTS MANUALSTANDARD MODEL DCA-800SSKDiesel engine exhaust and some of DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE 72-75 MQ Power DCA-600SSK AC GeneratorDCA-800SSKTABLE OF CONTENTS COMPONENT DRAWINGSOrder PARTS ORDERING PROCEDURESWhen ordering parts, please supply Choose from three easy optionsDCA-800SSK - SPECIFICATIONS Engine SpecificationsGenerator Specifications DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE NOTE PAGEFigure 1. Dimensions DCA-800SSK - DIMENSIONS TOP AND SIDEDCA-800SSK- DIMENSIONS FRONT , REAR AND DOORS Figure 2. DimensionsDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE Whisperwatt Generator DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS SAFETY MESSAGE ALERT SYMBOLSCAUTION - OVER-SPEED CONDITIONS DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - ACCIDENTAL STARTINGGenerator General SafetyDCA-800SSK - RULES FOR SAFE OPERATION DANGER - READTHIS MANUALDANGER - ELECTROCUTION HAZARDS Electrical SafetyDCA-800SSK - RULES FOR SAFE OPERATION Generator GroundingDCA-800SSK - RULES FOR SAFE OPERATION Maintenance SafetyBattery Safety DANGER - EXPLOSION HAZARDSALWAYS know the location of the nearest fire extinguisher Towing & Transporting SafetyEmergencies DCA-800SSK - RULES FOR SAFE OPERATIONFigure 3. Typical Generator Grounding Application DCA-800SSK - INSTALLATIONMounting DCA-800SSK - INSTALLATIONOutdoor Installation CAUTION - EXHAUST HAZARDFigure 4. Generator and Trailer Towing Safety PrecautionsDCA-800SSK -TOWING RULES FOR SAFE OPERATION CAUTION -TOWING REGULATIONSDCA-800SSK -TRAILER-SAFETY GUIDELINES Explanation of ChartCAUTION -TRAILER INSPECTION FUEL CELL DCA-800SSK -TRAILER-SPECIFICATIONSTable 3. Trailer Specifications MODELMODEL DCA-800SSK -TRAILER-SPECIFICATIONSTable 3. Specifications Cont DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEMachine Safety Decals DCA-800SSK - OPERATION AND SAFETY DECALSDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - OPERATION AND SAFETY DECALSDCA-800SSK - OPERATION AND SAFETY DECALS DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - OPERATION AND SAFETY DECALSEngine Control Panel Microprocessor Controlled Alarm SystemDCA-800SSK - GENERAL INFORMATION DCA-600SSK FAMILIARIZATION GeneratorDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - MAJOR COMPONENTSTable 4. Generator Major Components DESCRIPTIONUp to S/N S/N 3699248~ Figure 6. Generator Control Panel DCA-800SSK - GENERATOR CONTROL PANELDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - GENERATOR CONTROL PANELUp to S/N S/N 3699248~ Figure 7. Engine Operating Panels DCA-800SSK - ENGINE OPERATING PANELDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - ENGINE OPERATING PANELOutput Terminal Panel DCA-800SSK - OUTPUTTERMINAL OVERVIEWOutput Terminal Familiarization The “Output Terminal Panel ” Figure 8 is provided with the followingFigure 11. Voltage Regulator Control Knob DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW120VAC GFCI Receptacles Figure 9. G.F.C.I. ReceptacleOver Current Relay Connecting LoadsMaximum Power Output KW DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEWDCA-800SSK- LOAD APPLICATION Single Phase LoadTable 13. Power Factor By Load Three Phase LoadGenerator Amperage DCA-800SSK - GENERATOR OUTPUTSGenerator OutputVoltages Voltage Change-Over BoardFigure 19. AC Ammeter Change-Over Switch How to Read the OutputTerminal GaugeDCA-800SSK - GENERATOR OUTPUTS/GAUGE READING Maximum Amps1Ø-240V UVWO Terminal Output Voltages DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 3Ø-240V UVWO Terminal Output Voltages1Ø-277V UVWO Terminal Output Voltages DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS3Ø-480V UVWO Terminal Output Voltages 1Ø-480V UVWO Terminal Output VoltagesFuel Check DCA-800SSK - PRE-SETUPCircuit Breakers Lubrication Oilrefueling Refilling ProceduresCAUTION -TRAILER FUELTANK WARNING - RESPIRATORY HAZARDSFigure 37. Full Fuel System CAUTION - REFUELING SECONDARY FUELTANKDCA-800SSK - PRE-SETUP Figure 35. Full Trailer TankOperation Freezing Weather DCA-800SSK- PRE-SETUPCleaning the Radiator Air CleanerWiring BatteryBattery Cable Installation CAUTION - BATTERY SERVICING SAFETYGenerator and Control Panel DCA-800SSK - GEN. START-UP PROCEDURE MANUALBefore Starting CAUTION - LETHAL EXHAUST HAZARDFigure 46. Ignition Switch Pre-Heat DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL5. Set the battery ON/OFF switch Figure 45 to the “ON” position Figure 45. Battery ON/OFF SwitchFigure 50. Main, Aux. and GFCI Circuit Breakers ON DCA-800SSK - GENERATOR START-UP PROCEDURE MANUALFigure 48. Coolant Temperature Gauge Figure 47. Oil Pressure GaugeFigure 62. Engine Speed Switch High 20. Set the battery ON/OFF switch Figure 60 to the “ON” positionBEFORE STARTING Generator and Control Panel DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL2. Set the battery ON/OFF switch Figure 66 to the “ON” position DCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTOCAUTION - BACKUP GENERATOR USE WARNING - AUTO MODE MAINTENANCEEngine Shutdown Controller S/N 3698617~ DCA-600SSK - GENERATOR SHUT-DOWN PROCEDUREEmergency Shutdown Procedure WARNING - EMERGENCY STOP SWITCH250 Hrs DCA-800SSK - MAINTENANCEINSPECTION / MAINTENANCE 10 HrsOuter Element Service DailyCleaning the Fuel Strainer General InspectionDCA-800SSK - MAINTENANCE Flushing Out Radiator and Changing CoolantChanging Oil Replacing Fuel FilterRemoval From Long Term Storage Cleaning Breather ElementGreasing Generator StorageDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - MAINTENANCENOTEapplied to the generators internal battery charger Figure 75. Battery Charger/Jacket Water Heater Power ConnectionsBrake Drums or discs, Linings, and Hoses BrakesAir Brake System S-Cam BrakesTire Wear/Inflation DCA-800SSK -TRAILER MAINTENANCETires/Wheels/Lug Nuts CAUTION - EYESIGHT HAZARDTable 18. Tire Torque Requirements DCA-800SSK -TRAILER MAINTENANCELug NutTorque Requirements Figure 78. Wheel Lug Nuts Tightening SequenceDCA-800SSK -TRAILER-WIRING DIAGRAM Figure 79. Trailer Wiring Diagram 5-PinDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE Figure 80. Trailer Wiring Diagram 7-Pin DCA-800SSK -TRAILER-WIRING DIAGRAMDCA-800SSK - GENERATOR WIRING DIAGRAM Figure 81. Generator Wiring DiagramDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE Figure 82. Main Circuit Breaker Wiring Diagram DCA-800SSK - GENERATOR WIRING DIAGRAM MAIN BREAKERDCA-800SSK - ENGINE WIRING DIAGRAM Figure 83. Engine Wiring DiagramDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE Figure 84. Engine Wiring DiagramContinued DCA-800SSK - ENGINE WIRING DIAGRAMDCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM Figure 85. Electronic Governor ControllerDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE POSSIBLE PROBLEM DCA-600SSK -TROUBLESHOOTING ENGINETABLE 20. ENGINE TROUBLESHOOTING SYMPTOMPOSSIBLE PROBLEM DCA-800SSK -TROUBLESHOOTING ENGINETABLE 20. ENGINE TROUBLESHOOTING CONTINUED SYMPTOMPOSSIBLE PROBLEM DCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINETABLE 21. GENERATOR TROUBLESHOOTING SYMPTOMSympton DCA-800SSK -TROUBLESHOOTING MPECTABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC SolutionNO. Column EXPLANATION OF CODE IN REMARKS COLUMNSAMPLE PARTS LIST QTY. ColumnDCA-800SSK - SUGGESTED SPARE PARTS DescriptionDCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units GENERATOR ASSY DCA-800SSK - GENERATOR ASSYPART NAME QTY. REMARKSDCA-800SSK - GENERATOR ASSY DCA-800SSK - GENERATOR ASSY DCA-800SSK - GENERATOR ASSY PART NAMEQTY. REMARKS CONTROL PANEL ASSY DCA-800SSK - CONTROL PANEL ASSYS/N 3699248~ REPLACES DCA-800SSK - CONTROL PANEL ASSYREMARKS PART NAMECONTROL BOX ASSY DCA-800SSK - CONTROL BOX ASSYS/N 3692434 TO S/N DCA-800SSK - CONTROL BOX ASSYPART NAME REMARKSDCA-800SSK - CONTROL BOX ASSY CHANGE-OVER BOARD, VOLTAGE DCA-800SSK - CONTROL BOX ASSYPART NAME REMARKSENGINE AND RADIATOR ASSY DCA-800SSK - ENGINE AND RADIATOR ASSYDCA-800SSK - ENGINE AND RADIATOR ASSY PART NAMEREMARKS DCA-800SSK - ENGINE AND RADIATOR ASSY DCA-800SSK - ENGINE AND RADIATOR ASSY PART NAMEREMARKS OIL DRAIN ASSY DCA-800SSK - OIL DRAIN ASSYREMARKS DCA-800SSK - OIL DRAIN ASSYDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE PART NAMEENGINE OPERATING PANEL ASSY DCA-800SSK - ENGINE OPERATING PANEL ASSYDCA-800SSK - ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSYDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE OUTPUT TERMINAL ASSY DCA-800SSK - OUTPUTTERMINAL ASSYSET BOARD, OUTPUT TERMINAL DCA-800SSK - OUTPUTTERMINAL ASSYPART NAME BRACKET, OUTPUT TERMINALDCA-800SSK - OUTPUTTERMINAL ASSY C4237100504 DCA-800SSK - OUTPUTTERMINAL ASSYPART NAME REMARKSBATTERY ASSY DCA-800SSK - BATTERY ASSYPART NAME DCA-800SSK - BATTERY ASSYMUFFLER ASSY DCA-800SSK - MUFFLER ASSYPART NAME DCA-800SSK - MUFFLER ASSYFUEL TANK ASSY DCA-800SSK - FUELTANK ASSYCAP, FUEL TANK DCA-800SSK - FUELTANK ASSYPART NAME REMARKSPLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY DCA-800SSK - ENCLOSURE #1 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLORDCA-800SSK - ENCLOSURE #1 ASSY PART NAMEENCLOSURE #1 ASSY PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #1 ASSY OF ORANGE. TO ORDER WITH DIFFERENT COLORDCA-800SSK - ENCLOSURE #1 ASSY PART NAMEREMARKS PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY DCA-800SSK - ENCLOSURE #2 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLORDCA-800SSK - ENCLOSURE #2 ASSY PART NAMEENCLOSURE #2 ASSY PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #2 ASSY OF ORANGE. TO ORDER WITH DIFFERENT COLORDCA-800SSK - ENCLOSURE #2 ASSY PART NAMEREMARKS PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY DCA-800SSK - ENCLOSURE #3 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLORENCLOSURE #3 ASSY DCA-800SSK - ENCLOSURE #3 ASSYPART NAME QTY. REMARKSPLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY THE PART NUMBER ABOVE INDICATES DEFAULT COLORDCA-800SSK - ENCLOSURE #3 ASSY OF ORANGE. TO ORDER WITH DIFFERENT COLORPART NAME DCA-800SSK - ENCLOSURE #3 ASSYRUBBER SEALS ASSY DCA-800SSK - RUBBER SEALS ASSYDCA-800SSK - RUBBER SEALS ASSY PART NAMERUBBER SEALS ASSY NAME PLATE AND DECALS DCA-800SSK - NAME PLATE AND DECALSPART NAME PROCEDURE GROUPCONTROL PANEL GROUP DCA-800SSK - NAME PLATE AND DECALSDCA-800SSK - NAME PLATE AND DECALS OIL DRAIN GROUP BATTERY GROUPDCA-800SSK - NAME PLATE AND DECALS ENGINE & RADIATOR GROUPFREIGHT POLICY TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE NOTE PAGEContact mqpower@multiquip.com HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING MQ Power