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operation manual DCA-800SSK - ENGINE WIRING DIAGRAM, Engine Wiring Diagram
Models:
DCA-800SSK
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63
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Troubleshooting
Specification
Install
Parts list
Explanation of Chart
Warranty
Dimension
Maintenance
Voltage Change-Over Board 240V Configuration
Connecting Loads
Page 63
Image 63
DCA-800SSK
— ENGINE WIRING DIAGRAM
Figure 83. Engine Wiring Diagram
DCA-800SSK
(STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 63
Page 62
Page 64
Page 63
Image 63
Page 62
Page 64
Contents
PORTABLE GENERATOR
OPERATION AND PARTS MANUAL
STANDARD
MODEL DCA-800SSK
Diesel 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 Generator
DCA-800SSKTABLE OF CONTENTS
COMPONENT DRAWINGS
Order
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Choose from three easy options
DCA-800SSK - SPECIFICATIONS
Engine Specifications
Generator Specifications
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
NOTE PAGE
Figure 1. Dimensions
DCA-800SSK - DIMENSIONS TOP AND SIDE
DCA-800SSK- DIMENSIONS FRONT , REAR AND DOORS
Figure 2. Dimensions
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
Whisperwatt Generator
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
CAUTION - OVER-SPEED CONDITIONS
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
Generator
General Safety
DCA-800SSK - RULES FOR SAFE OPERATION
DANGER - READTHIS MANUAL
DANGER - ELECTROCUTION HAZARDS
Electrical Safety
DCA-800SSK - RULES FOR SAFE OPERATION
Generator Grounding
DCA-800SSK - RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
DANGER - EXPLOSION HAZARDS
ALWAYS know the location of the nearest fire extinguisher
Towing & Transporting Safety
Emergencies
DCA-800SSK - RULES FOR SAFE OPERATION
Figure 3. Typical Generator Grounding Application
DCA-800SSK - INSTALLATION
Mounting
DCA-800SSK - INSTALLATION
Outdoor Installation
CAUTION - EXHAUST HAZARD
Figure 4. Generator and Trailer
Towing Safety Precautions
DCA-800SSK -TOWING RULES FOR SAFE OPERATION
CAUTION -TOWING REGULATIONS
DCA-800SSK -TRAILER-SAFETY GUIDELINES
Explanation of Chart
CAUTION -TRAILER INSPECTION
FUEL CELL
DCA-800SSK -TRAILER-SPECIFICATIONS
Table 3. Trailer Specifications
MODEL
MODEL
DCA-800SSK -TRAILER-SPECIFICATIONS
Table 3. Specifications Cont
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
Machine Safety Decals
DCA-800SSK - OPERATION AND SAFETY DECALS
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - OPERATION AND SAFETY DECALS
DCA-800SSK - OPERATION AND SAFETY DECALS
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - OPERATION AND SAFETY DECALS
Engine Control Panel
Microprocessor Controlled Alarm System
DCA-800SSK - GENERAL INFORMATION
DCA-600SSK FAMILIARIZATION Generator
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - MAJOR COMPONENTS
Table 4. Generator Major Components
DESCRIPTION
Up to S/N S/N 3699248~ Figure 6. Generator Control Panel
DCA-800SSK - GENERATOR CONTROL PANEL
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - GENERATOR CONTROL PANEL
Up to S/N S/N 3699248~ Figure 7. Engine Operating Panels
DCA-800SSK - ENGINE OPERATING PANEL
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ENGINE OPERATING PANEL
Output Terminal Panel
DCA-800SSK - OUTPUTTERMINAL OVERVIEW
Output Terminal Familiarization
The “Output Terminal Panel ” Figure 8 is provided with the following
Figure 11. Voltage Regulator Control Knob
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
120VAC GFCI Receptacles
Figure 9. G.F.C.I. Receptacle
Over Current Relay
Connecting Loads
Maximum Power Output KW
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
DCA-800SSK- LOAD APPLICATION
Single Phase Load
Table 13. Power Factor By Load
Three Phase Load
Generator Amperage
DCA-800SSK - GENERATOR OUTPUTS
Generator OutputVoltages
Voltage Change-Over Board
Figure 19. AC Ammeter Change-Over Switch
How to Read the OutputTerminal Gauge
DCA-800SSK - GENERATOR OUTPUTS/GAUGE READING
Maximum Amps
1Ø-240V UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
3Ø-240V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
Fuel Check
DCA-800SSK - PRE-SETUP
Circuit Breakers
Lubrication Oil
refueling
Refilling Procedures
CAUTION -TRAILER FUELTANK
WARNING - RESPIRATORY HAZARDS
Figure 37. Full Fuel System
CAUTION - REFUELING SECONDARY FUELTANK
DCA-800SSK - PRE-SETUP
Figure 35. Full Trailer Tank
Operation Freezing Weather
DCA-800SSK- PRE-SETUP
Cleaning the Radiator
Air Cleaner
Wiring
Battery
Battery Cable Installation
CAUTION - BATTERY SERVICING SAFETY
Generator and Control Panel
DCA-800SSK - GEN. START-UP PROCEDURE MANUAL
Before Starting
CAUTION - LETHAL EXHAUST HAZARD
Figure 46. Ignition Switch Pre-Heat
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
5. Set the battery ON/OFF switch Figure 45 to the “ON” position
Figure 45. Battery ON/OFF Switch
Figure 50. Main, Aux. and GFCI Circuit Breakers ON
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 48. Coolant Temperature Gauge
Figure 47. Oil Pressure Gauge
Figure 62. Engine Speed Switch High
20. Set the battery ON/OFF switch Figure 60 to the “ON” position
BEFORE STARTING Generator and Control Panel
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
2. Set the battery ON/OFF switch Figure 66 to the “ON” position
DCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTO
CAUTION - BACKUP GENERATOR USE
WARNING - AUTO MODE MAINTENANCE
Engine Shutdown Controller S/N 3698617~
DCA-600SSK - GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
WARNING - EMERGENCY STOP SWITCH
250 Hrs
DCA-800SSK - MAINTENANCE
INSPECTION / MAINTENANCE
10 Hrs
Outer Element
Service Daily
Cleaning the Fuel Strainer
General Inspection
DCA-800SSK - MAINTENANCE
Flushing Out Radiator and Changing Coolant
Changing Oil
Replacing Fuel Filter
Removal From Long Term Storage
Cleaning Breather Element
Greasing
Generator Storage
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - MAINTENANCE
NOTEapplied to the generators internal battery charger
Figure 75. Battery Charger/Jacket Water Heater Power Connections
Brake Drums or discs, Linings, and Hoses
Brakes
Air Brake System
S-Cam Brakes
Tire Wear/Inflation
DCA-800SSK -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
Table 18. Tire Torque Requirements
DCA-800SSK -TRAILER MAINTENANCE
Lug NutTorque Requirements
Figure 78. Wheel Lug Nuts Tightening Sequence
DCA-800SSK -TRAILER-WIRING DIAGRAM
Figure 79. Trailer Wiring Diagram 5-Pin
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
Figure 80. Trailer Wiring Diagram 7-Pin
DCA-800SSK -TRAILER-WIRING DIAGRAM
DCA-800SSK - GENERATOR WIRING DIAGRAM
Figure 81. Generator Wiring Diagram
DCA-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 BREAKER
DCA-800SSK - ENGINE WIRING DIAGRAM
Figure 83. Engine Wiring Diagram
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
Figure 84. Engine Wiring DiagramContinued
DCA-800SSK - ENGINE WIRING DIAGRAM
DCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM
Figure 85. Electronic Governor Controller
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
POSSIBLE PROBLEM
DCA-600SSK -TROUBLESHOOTING ENGINE
TABLE 20. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
DCA-800SSK -TROUBLESHOOTING ENGINE
TABLE 20. ENGINE TROUBLESHOOTING CONTINUED
SYMPTOM
POSSIBLE PROBLEM
DCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINE
TABLE 21. GENERATOR TROUBLESHOOTING
SYMPTOM
Sympton
DCA-800SSK -TROUBLESHOOTING MPEC
TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Solution
NO. Column
EXPLANATION OF CODE IN REMARKS COLUMN
SAMPLE PARTS LIST
QTY. Column
DCA-800SSK - SUGGESTED SPARE PARTS
Description
DCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units
GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
PART NAME
QTY. REMARKS
DCA-800SSK - GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
PART NAME
QTY. REMARKS
CONTROL PANEL ASSY
DCA-800SSK - CONTROL PANEL ASSY
S/N 3699248~ REPLACES
DCA-800SSK - CONTROL PANEL ASSY
REMARKS
PART NAME
CONTROL BOX ASSY
DCA-800SSK - CONTROL BOX ASSY
S/N 3692434 TO S/N
DCA-800SSK - CONTROL BOX ASSY
PART NAME
REMARKS
DCA-800SSK - CONTROL BOX ASSY
CHANGE-OVER BOARD, VOLTAGE
DCA-800SSK - CONTROL BOX ASSY
PART NAME
REMARKS
ENGINE AND RADIATOR ASSY
DCA-800SSK - ENGINE AND RADIATOR ASSY
DCA-800SSK - ENGINE AND RADIATOR ASSY
PART NAME
REMARKS
DCA-800SSK - ENGINE AND RADIATOR ASSY
DCA-800SSK - ENGINE AND RADIATOR ASSY
PART NAME
REMARKS
OIL DRAIN ASSY
DCA-800SSK - OIL DRAIN ASSY
REMARKS
DCA-800SSK - OIL DRAIN ASSY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
PART NAME
ENGINE OPERATING PANEL ASSY
DCA-800SSK - ENGINE OPERATING PANEL ASSY
DCA-800SSK - ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
OUTPUT TERMINAL ASSY
DCA-800SSK - OUTPUTTERMINAL ASSY
SET BOARD, OUTPUT TERMINAL
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
BRACKET, OUTPUT TERMINAL
DCA-800SSK - OUTPUTTERMINAL ASSY
C4237100504
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
REMARKS
BATTERY ASSY
DCA-800SSK - BATTERY ASSY
PART NAME
DCA-800SSK - BATTERY ASSY
MUFFLER ASSY
DCA-800SSK - MUFFLER ASSY
PART NAME
DCA-800SSK - MUFFLER ASSY
FUEL TANK ASSY
DCA-800SSK - FUELTANK ASSY
CAP, FUEL TANK
DCA-800SSK - FUELTANK ASSY
PART NAME
REMARKS
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
DCA-800SSK - ENCLOSURE #1 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
ENCLOSURE #1 ASSY
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
REMARKS
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
DCA-800SSK - ENCLOSURE #2 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
ENCLOSURE #2 ASSY
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
REMARKS
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
DCA-800SSK - ENCLOSURE #3 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
ENCLOSURE #3 ASSY
DCA-800SSK - ENCLOSURE #3 ASSY
PART NAME
QTY. REMARKS
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #3 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PART NAME
DCA-800SSK - ENCLOSURE #3 ASSY
RUBBER SEALS ASSY
DCA-800SSK - RUBBER SEALS ASSY
DCA-800SSK - RUBBER SEALS ASSY
PART NAME
RUBBER SEALS ASSY
NAME PLATE AND DECALS
DCA-800SSK - NAME PLATE AND DECALS
PART NAME
PROCEDURE GROUP
CONTROL PANEL GROUP
DCA-800SSK - NAME PLATE AND DECALS
DCA-800SSK - NAME PLATE AND DECALS
OIL DRAIN GROUP
BATTERY GROUP
DCA-800SSK - NAME PLATE AND DECALS
ENGINE & RADIATOR GROUP
FREIGHT POLICY
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
PAYMENT TERMS
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
NOTE PAGE
Contact mqpower@multiquip.com
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
MQ Power