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operation manual DCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM
Models:
DCA-800SSK
1
65
120
120
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Troubleshooting
Specifications
Install
Parts list
Explanation of Chart
Warranty
Dimension
Maintenance
Voltage Change-Over Board 240V Configuration
Connecting Loads
Page 65
Image 65
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 65
Page 64
Page 66
Page 65
Image 65
Page 64
Page 66
Contents
STANDARD
OPERATION AND PARTS MANUAL
MODEL DCA-800SSK
PORTABLE GENERATOR
Diesel engine exhaust and some of
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSKTABLE OF CONTENTS
MQ Power DCA-600SSK AC Generator
COMPONENT DRAWINGS
72-75
When ordering parts, please supply
PARTS ORDERING PROCEDURES
Choose from three easy options
Order
Generator Specifications
DCA-800SSK - SPECIFICATIONS
Engine 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 STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK- DIMENSIONS FRONT , REAR AND DOORS
Figure 2. Dimensions
HAZARD SYMBOLS
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
Whisperwatt Generator
WARNING - ROTATING PARTS
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
CAUTION - ACCIDENTAL STARTING
CAUTION - OVER-SPEED CONDITIONS
DCA-800SSK - RULES FOR SAFE OPERATION
General Safety
DANGER - READTHIS MANUAL
Generator
DCA-800SSK - RULES FOR SAFE OPERATION
Electrical Safety
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
Battery Safety
Maintenance Safety
DANGER - EXPLOSION HAZARDS
DCA-800SSK - RULES FOR SAFE OPERATION
Emergencies
Towing & Transporting Safety
DCA-800SSK - RULES FOR SAFE OPERATION
ALWAYS know the location of the nearest fire extinguisher
Figure 3. Typical Generator Grounding Application
DCA-800SSK - INSTALLATION
Outdoor Installation
DCA-800SSK - INSTALLATION
CAUTION - EXHAUST HAZARD
Mounting
DCA-800SSK -TOWING RULES FOR SAFE OPERATION
Towing Safety Precautions
CAUTION -TOWING REGULATIONS
Figure 4. Generator and Trailer
CAUTION -TRAILER INSPECTION
DCA-800SSK -TRAILER-SAFETY GUIDELINES
Explanation of Chart
Table 3. Trailer Specifications
DCA-800SSK -TRAILER-SPECIFICATIONS
MODEL
FUEL CELL
Table 3. Specifications Cont
DCA-800SSK -TRAILER-SPECIFICATIONS
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
MODEL
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
DCA-800SSK - GENERAL INFORMATION
Microprocessor Controlled Alarm System
DCA-600SSK FAMILIARIZATION Generator
Engine Control Panel
Table 4. Generator Major Components
DCA-800SSK - MAJOR COMPONENTS
DESCRIPTION
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
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 Familiarization
DCA-800SSK - OUTPUTTERMINAL OVERVIEW
The “Output Terminal Panel ” Figure 8 is provided with the following
Output Terminal Panel
120VAC GFCI Receptacles
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
Figure 9. G.F.C.I. Receptacle
Figure 11. Voltage Regulator Control Knob
Maximum Power Output KW
Connecting Loads
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
Over Current Relay
Table 13. Power Factor By Load
Single Phase Load
Three Phase Load
DCA-800SSK- LOAD APPLICATION
Generator OutputVoltages
DCA-800SSK - GENERATOR OUTPUTS
Voltage Change-Over Board
Generator Amperage
DCA-800SSK - GENERATOR OUTPUTS/GAUGE READING
How to Read the OutputTerminal Gauge
Maximum Amps
Figure 19. AC Ammeter Change-Over Switch
UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-240V UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
3Ø-480V UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
1Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
Circuit Breakers
DCA-800SSK - PRE-SETUP
Lubrication Oil
Fuel Check
CAUTION -TRAILER FUELTANK
Refilling Procedures
WARNING - RESPIRATORY HAZARDS
refueling
DCA-800SSK - PRE-SETUP
CAUTION - REFUELING SECONDARY FUELTANK
Figure 35. Full Trailer Tank
Figure 37. Full Fuel System
Cleaning the Radiator
DCA-800SSK- PRE-SETUP
Air Cleaner
Operation Freezing Weather
Battery Cable Installation
Battery
CAUTION - BATTERY SERVICING SAFETY
Wiring
Before Starting
DCA-800SSK - GEN. START-UP PROCEDURE MANUAL
CAUTION - LETHAL EXHAUST HAZARD
Generator and Control Panel
5. Set the battery ON/OFF switch Figure 45 to the “ON” position
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 45. Battery ON/OFF Switch
Figure 46. Ignition Switch Pre-Heat
Figure 48. Coolant Temperature Gauge
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 47. Oil Pressure Gauge
Figure 50. Main, Aux. and GFCI Circuit Breakers ON
BEFORE STARTING Generator and Control Panel
20. Set the battery ON/OFF switch Figure 60 to the “ON” position
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 62. Engine Speed Switch High
CAUTION - BACKUP GENERATOR USE
DCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTO
WARNING - AUTO MODE MAINTENANCE
2. Set the battery ON/OFF switch Figure 66 to the “ON” position
Emergency Shutdown Procedure
DCA-600SSK - GENERATOR SHUT-DOWN PROCEDURE
WARNING - EMERGENCY STOP SWITCH
Engine Shutdown Controller S/N 3698617~
INSPECTION / MAINTENANCE
DCA-800SSK - MAINTENANCE
10 Hrs
250 Hrs
Cleaning the Fuel Strainer
Service Daily
General Inspection
Outer Element
Changing Oil
Flushing Out Radiator and Changing Coolant
Replacing Fuel Filter
DCA-800SSK - MAINTENANCE
Greasing
Cleaning Breather Element
Generator Storage
Removal From Long Term Storage
NOTEapplied to the generators internal battery charger
DCA-800SSK - MAINTENANCE
Figure 75. Battery Charger/Jacket Water Heater Power Connections
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
Air Brake System
Brakes
S-Cam Brakes
Brake Drums or discs, Linings, and Hoses
Tires/Wheels/Lug Nuts
DCA-800SSK -TRAILER MAINTENANCE
CAUTION - EYESIGHT HAZARD
Tire Wear/Inflation
Lug NutTorque Requirements
DCA-800SSK -TRAILER MAINTENANCE
Figure 78. Wheel Lug Nuts Tightening Sequence
Table 18. Tire Torque Requirements
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK -TRAILER-WIRING DIAGRAM
Figure 79. Trailer Wiring Diagram 5-Pin
Figure 80. Trailer Wiring Diagram 7-Pin
DCA-800SSK -TRAILER-WIRING DIAGRAM
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - GENERATOR WIRING DIAGRAM
Figure 81. Generator Wiring Diagram
Figure 82. Main Circuit Breaker Wiring Diagram
DCA-800SSK - GENERATOR WIRING DIAGRAM MAIN BREAKER
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ENGINE WIRING DIAGRAM
Figure 83. Engine Wiring Diagram
Figure 84. Engine Wiring DiagramContinued
DCA-800SSK - ENGINE WIRING DIAGRAM
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM
Figure 85. Electronic Governor Controller
TABLE 20. ENGINE TROUBLESHOOTING
DCA-600SSK -TROUBLESHOOTING ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 20. ENGINE TROUBLESHOOTING CONTINUED
DCA-800SSK -TROUBLESHOOTING ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 21. GENERATOR TROUBLESHOOTING
DCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC
DCA-800SSK -TROUBLESHOOTING MPEC
Solution
Sympton
SAMPLE PARTS LIST
EXPLANATION OF CODE IN REMARKS COLUMN
QTY. Column
NO. Column
DCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units
DCA-800SSK - SUGGESTED SPARE PARTS
Description
GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
PART NAME
QTY. REMARKS
DCA-800SSK - GENERATOR ASSY
QTY. REMARKS
DCA-800SSK - GENERATOR ASSY
PART NAME
CONTROL PANEL ASSY
DCA-800SSK - CONTROL PANEL ASSY
REMARKS
DCA-800SSK - CONTROL PANEL ASSY
PART NAME
S/N 3699248~ REPLACES
CONTROL BOX ASSY
DCA-800SSK - CONTROL BOX ASSY
PART NAME
DCA-800SSK - CONTROL BOX ASSY
REMARKS
S/N 3692434 TO S/N
DCA-800SSK - CONTROL BOX ASSY
PART NAME
DCA-800SSK - CONTROL BOX ASSY
REMARKS
CHANGE-OVER BOARD, VOLTAGE
ENGINE AND RADIATOR ASSY
DCA-800SSK - ENGINE AND RADIATOR ASSY
REMARKS
DCA-800SSK - ENGINE AND RADIATOR ASSY
PART NAME
DCA-800SSK - ENGINE AND RADIATOR ASSY
REMARKS
DCA-800SSK - ENGINE AND RADIATOR ASSY
PART NAME
OIL DRAIN ASSY
DCA-800SSK - OIL DRAIN ASSY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - OIL DRAIN ASSY
PART NAME
REMARKS
ENGINE OPERATING PANEL ASSY
DCA-800SSK - ENGINE OPERATING PANEL ASSY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
OUTPUT TERMINAL ASSY
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
DCA-800SSK - OUTPUTTERMINAL ASSY
BRACKET, OUTPUT TERMINAL
SET BOARD, OUTPUT TERMINAL
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
DCA-800SSK - OUTPUTTERMINAL ASSY
REMARKS
C4237100504
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
PART NAME
DCA-800SSK - FUELTANK ASSY
REMARKS
CAP, FUEL TANK
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
ENCLOSURE #1 ASSY
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
DCA-800SSK - ENCLOSURE #1 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
REMARKS
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
ENCLOSURE #2 ASSY
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
DCA-800SSK - ENCLOSURE #2 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
REMARKS
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #3 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
PART NAME
DCA-800SSK - ENCLOSURE #3 ASSY
QTY. REMARKS
ENCLOSURE #3 ASSY
DCA-800SSK - ENCLOSURE #3 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
PART NAME
DCA-800SSK - ENCLOSURE #3 ASSY
RUBBER SEALS ASSY
DCA-800SSK - RUBBER SEALS ASSY
RUBBER SEALS ASSY
DCA-800SSK - RUBBER SEALS ASSY
PART NAME
NAME PLATE AND DECALS
DCA-800SSK - NAME PLATE AND DECALS
CONTROL PANEL GROUP
PROCEDURE GROUP
DCA-800SSK - NAME PLATE AND DECALS
PART NAME
DCA-800SSK - NAME PLATE AND DECALS
DCA-800SSK - NAME PLATE AND DECALS
BATTERY GROUP
ENGINE & RADIATOR GROUP
OIL DRAIN GROUP
SPECIAL EXPEDITING SERVICE
TERMS AND CONDITIONS OF SALE - PARTS
PAYMENT TERMS
FREIGHT POLICY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
NOTE PAGE
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERE’S HOW TO GET HELP
MQ Power
Contact mqpower@multiquip.com