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operation manual DCA-800SSK - OIL DRAIN ASSY, Oil Drain Assy
Models:
DCA-800SSK
1
86
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 86
Image 86
DCA-800SSK
— OIL DRAIN ASSY.
OIL DRAIN ASSY.
PAGE 86 —
DCA-800SSK
(STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)
Page 85
Page 87
Page 86
Image 86
Page 85
Page 87
Contents
MODEL DCA-800SSK
OPERATION AND PARTS MANUAL
STANDARD
PORTABLE GENERATOR
Diesel 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 Generator
DCA-800SSKTABLE OF CONTENTS
72-75
Choose from three easy options
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Order
Generator Specifications
DCA-800SSK - SPECIFICATIONS
Engine Specifications
NOTE PAGE
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - DIMENSIONS TOP AND SIDE
Figure 1. Dimensions
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK- DIMENSIONS FRONT , REAR AND DOORS
Figure 2. Dimensions
SAFETY MESSAGE ALERT SYMBOLS
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
Whisperwatt Generator
CAUTION - ACCIDENTAL STARTING
DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - OVER-SPEED CONDITIONS
DANGER - READTHIS MANUAL
General Safety
DCA-800SSK - RULES FOR SAFE OPERATION
Generator
Generator Grounding
Electrical Safety
DCA-800SSK - RULES FOR SAFE OPERATION
DANGER - ELECTROCUTION HAZARDS
DANGER - EXPLOSION HAZARDS
Maintenance Safety
Battery Safety
DCA-800SSK - RULES FOR SAFE OPERATION
DCA-800SSK - RULES FOR SAFE OPERATION
Towing & Transporting Safety
Emergencies
ALWAYS know the location of the nearest fire extinguisher
DCA-800SSK - INSTALLATION
Figure 3. Typical Generator Grounding Application
CAUTION - EXHAUST HAZARD
DCA-800SSK - INSTALLATION
Outdoor Installation
Mounting
CAUTION -TOWING REGULATIONS
Towing Safety Precautions
DCA-800SSK -TOWING RULES FOR SAFE OPERATION
Figure 4. Generator and Trailer
CAUTION -TRAILER INSPECTION
DCA-800SSK -TRAILER-SAFETY GUIDELINES
Explanation of Chart
MODEL
DCA-800SSK -TRAILER-SPECIFICATIONS
Table 3. Trailer Specifications
FUEL CELL
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK -TRAILER-SPECIFICATIONS
Table 3. Specifications Cont
MODEL
DCA-800SSK - OPERATION AND SAFETY DECALS
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-600SSK FAMILIARIZATION Generator
Microprocessor Controlled Alarm System
DCA-800SSK - GENERAL INFORMATION
Engine Control Panel
DESCRIPTION
DCA-800SSK - MAJOR COMPONENTS
Table 4. Generator Major Components
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 6. Generator Control Panel
DCA-800SSK - GENERATOR CONTROL PANEL
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ENGINE OPERATING 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
The “Output Terminal Panel ” Figure 8 is provided with the following
DCA-800SSK - OUTPUTTERMINAL OVERVIEW
Output Terminal Familiarization
Output Terminal Panel
Figure 9. G.F.C.I. Receptacle
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
120VAC GFCI Receptacles
Figure 11. Voltage Regulator Control Knob
DCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW
Connecting Loads
Maximum Power Output KW
Over Current Relay
Three Phase Load
Single Phase Load
Table 13. Power Factor By Load
DCA-800SSK- LOAD APPLICATION
Voltage Change-Over Board
DCA-800SSK - GENERATOR OUTPUTS
Generator OutputVoltages
Generator Amperage
Maximum Amps
How to Read the OutputTerminal Gauge
DCA-800SSK - GENERATOR OUTPUTS/GAUGE READING
Figure 19. AC Ammeter Change-Over Switch
3Ø-240V UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
DCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
1Ø-277V UVWO Terminal Output Voltages
Lubrication Oil
DCA-800SSK - PRE-SETUP
Circuit Breakers
Fuel Check
WARNING - RESPIRATORY HAZARDS
Refilling Procedures
CAUTION -TRAILER FUELTANK
refueling
Figure 35. Full Trailer Tank
CAUTION - REFUELING SECONDARY FUELTANK
DCA-800SSK - PRE-SETUP
Figure 37. Full Fuel System
Air Cleaner
DCA-800SSK- PRE-SETUP
Cleaning the Radiator
Operation Freezing Weather
CAUTION - BATTERY SERVICING SAFETY
Battery
Battery Cable Installation
Wiring
CAUTION - LETHAL EXHAUST HAZARD
DCA-800SSK - GEN. START-UP PROCEDURE MANUAL
Before Starting
Generator and Control Panel
Figure 45. Battery ON/OFF Switch
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
5. Set the battery ON/OFF switch Figure 45 to the “ON” position
Figure 46. Ignition Switch Pre-Heat
Figure 47. Oil Pressure Gauge
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 48. Coolant Temperature Gauge
Figure 50. Main, Aux. and GFCI Circuit Breakers ON
DCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL
20. Set the battery ON/OFF switch Figure 60 to the “ON” position
BEFORE STARTING Generator and Control Panel
Figure 62. Engine Speed Switch High
WARNING - AUTO MODE MAINTENANCE
DCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTO
CAUTION - BACKUP GENERATOR USE
2. Set the battery ON/OFF switch Figure 66 to the “ON” position
WARNING - EMERGENCY STOP SWITCH
DCA-600SSK - GENERATOR SHUT-DOWN PROCEDURE
Emergency Shutdown Procedure
Engine Shutdown Controller S/N 3698617~
10 Hrs
DCA-800SSK - MAINTENANCE
INSPECTION / MAINTENANCE
250 Hrs
General Inspection
Service Daily
Cleaning the Fuel Strainer
Outer Element
Replacing Fuel Filter
Flushing Out Radiator and Changing Coolant
Changing Oil
DCA-800SSK - MAINTENANCE
Generator Storage
Cleaning Breather Element
Greasing
Removal From Long Term Storage
Figure 75. Battery Charger/Jacket Water Heater Power Connections
DCA-800SSK - MAINTENANCE
NOTEapplied to the generators internal battery charger
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
S-Cam Brakes
Brakes
Air Brake System
Brake Drums or discs, Linings, and Hoses
CAUTION - EYESIGHT HAZARD
DCA-800SSK -TRAILER MAINTENANCE
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Figure 78. Wheel Lug Nuts Tightening Sequence
DCA-800SSK -TRAILER MAINTENANCE
Lug NutTorque Requirements
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
DCA-800SSK -TRAILER-WIRING DIAGRAM
Figure 80. Trailer Wiring Diagram 7-Pin
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - GENERATOR WIRING DIAGRAM
Figure 81. Generator Wiring Diagram
DCA-800SSK - GENERATOR WIRING DIAGRAM MAIN BREAKER
Figure 82. Main Circuit Breaker Wiring Diagram
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
DCA-800SSK - ENGINE WIRING DIAGRAM
Figure 83. Engine Wiring Diagram
DCA-800SSK - ENGINE WIRING DIAGRAM
Figure 84. Engine Wiring DiagramContinued
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
SYMPTOM
DCA-600SSK -TROUBLESHOOTING ENGINE
TABLE 20. ENGINE TROUBLESHOOTING
POSSIBLE PROBLEM
SYMPTOM
DCA-800SSK -TROUBLESHOOTING ENGINE
TABLE 20. ENGINE TROUBLESHOOTING CONTINUED
POSSIBLE PROBLEM
SYMPTOM
DCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINE
TABLE 21. GENERATOR TROUBLESHOOTING
POSSIBLE PROBLEM
Solution
DCA-800SSK -TROUBLESHOOTING MPEC
TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPEC
Sympton
QTY. Column
EXPLANATION OF CODE IN REMARKS COLUMN
SAMPLE PARTS LIST
NO. Column
DCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units
DCA-800SSK - SUGGESTED SPARE PARTS
Description
DCA-800SSK - GENERATOR ASSY
GENERATOR ASSY
DCA-800SSK - GENERATOR ASSY
PART NAME
QTY. REMARKS
DCA-800SSK - GENERATOR ASSY
QTY. REMARKS
DCA-800SSK - GENERATOR ASSY
PART NAME
DCA-800SSK - CONTROL PANEL ASSY
CONTROL PANEL ASSY
PART NAME
DCA-800SSK - CONTROL PANEL ASSY
REMARKS
S/N 3699248~ REPLACES
DCA-800SSK - CONTROL BOX ASSY
CONTROL BOX ASSY
REMARKS
DCA-800SSK - CONTROL BOX ASSY
PART NAME
S/N 3692434 TO S/N
DCA-800SSK - CONTROL BOX ASSY
REMARKS
DCA-800SSK - CONTROL BOX ASSY
PART NAME
CHANGE-OVER BOARD, VOLTAGE
DCA-800SSK - ENGINE AND RADIATOR ASSY
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
DCA-800SSK - OIL DRAIN ASSY
OIL DRAIN ASSY
PART NAME
DCA-800SSK - OIL DRAIN ASSY
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
REMARKS
DCA-800SSK - ENGINE OPERATING PANEL ASSY
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
DCA-800SSK - OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
BRACKET, OUTPUT TERMINAL
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
SET BOARD, OUTPUT TERMINAL
DCA-800SSK - OUTPUTTERMINAL ASSY
REMARKS
DCA-800SSK - OUTPUTTERMINAL ASSY
PART NAME
C4237100504
DCA-800SSK - BATTERY ASSY
BATTERY ASSY
DCA-800SSK - BATTERY ASSY
PART NAME
DCA-800SSK - MUFFLER ASSY
MUFFLER ASSY
DCA-800SSK - MUFFLER ASSY
PART NAME
DCA-800SSK - FUELTANK ASSY
FUEL TANK ASSY
REMARKS
DCA-800SSK - FUELTANK ASSY
PART NAME
CAP, FUEL TANK
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
ENCLOSURE #1 ASSY
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #1 ASSY
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
REMARKS
DCA-800SSK - ENCLOSURE #1 ASSY
PART NAME
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
ENCLOSURE #2 ASSY
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #2 ASSY
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
REMARKS
DCA-800SSK - ENCLOSURE #2 ASSY
PART NAME
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
DCA-800SSK - ENCLOSURE #3 ASSY
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
QTY. REMARKS
DCA-800SSK - ENCLOSURE #3 ASSY
PART NAME
ENCLOSURE #3 ASSY
OF ORANGE. TO ORDER WITH DIFFERENT COLOR
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
DCA-800SSK - ENCLOSURE #3 ASSY
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAY
DCA-800SSK - ENCLOSURE #3 ASSY
PART NAME
DCA-800SSK - RUBBER SEALS ASSY
RUBBER SEALS ASSY
RUBBER SEALS ASSY
DCA-800SSK - RUBBER SEALS ASSY
PART NAME
DCA-800SSK - NAME PLATE AND DECALS
NAME PLATE AND DECALS
DCA-800SSK - NAME PLATE AND DECALS
PROCEDURE GROUP
CONTROL PANEL GROUP
PART NAME
DCA-800SSK - NAME PLATE AND DECALS
ENGINE & RADIATOR GROUP
BATTERY GROUP
DCA-800SSK - NAME PLATE AND DECALS
OIL DRAIN GROUP
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
NOTE PAGE
DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE
MQ Power
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
Contact mqpower@multiquip.com