Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip operation manual DCA-800SSK - MUFFLER ASSY, Muffler Assy

Models: DCA-800SSK

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Page 96

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DCA-800SSK — MUFFLER ASSY.

MUFFLER ASSY.

PAGE 96 — DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10)

Page 96

Image 96

Multiquip operation manual DCA-800SSK - MUFFLER ASSY, Muffler Assy

Contents

OPERATION AND PARTS MANUAL STANDARDMODEL DCA-800SSK PORTABLE GENERATORDiesel engine exhaust and some of DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE MQ Power DCA-600SSK AC Generator DCA-800SSKTABLE OF CONTENTSCOMPONENT DRAWINGS 72-75PARTS ORDERING PROCEDURES When ordering parts, please supplyChoose from three easy options OrderDCA-800SSK - SPECIFICATIONS Engine SpecificationsGenerator 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- DIMENSIONS FRONT , REAR AND DOORS Figure 2. DimensionsDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSSAFETY MESSAGE ALERT SYMBOLS Whisperwatt GeneratorDCA-800SSK - SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - OVER-SPEED CONDITIONSGeneral Safety DCA-800SSK - RULES FOR SAFE OPERATIONDANGER - READTHIS MANUAL GeneratorElectrical Safety DCA-800SSK - RULES FOR SAFE OPERATIONGenerator Grounding DANGER - ELECTROCUTION HAZARDSMaintenance Safety Battery SafetyDANGER - EXPLOSION HAZARDS DCA-800SSK - RULES FOR SAFE OPERATIONTowing & Transporting Safety EmergenciesDCA-800SSK - RULES FOR SAFE OPERATION ALWAYS know the location of the nearest fire extinguisherDCA-800SSK - INSTALLATION Figure 3. Typical Generator Grounding ApplicationDCA-800SSK - INSTALLATION Outdoor InstallationCAUTION - EXHAUST HAZARD MountingTowing Safety Precautions DCA-800SSK -TOWING RULES FOR SAFE OPERATIONCAUTION -TOWING REGULATIONS Figure 4. Generator and TrailerDCA-800SSK -TRAILER-SAFETY GUIDELINES Explanation of ChartCAUTION -TRAILER INSPECTION DCA-800SSK -TRAILER-SPECIFICATIONS Table 3. Trailer SpecificationsMODEL FUEL CELLDCA-800SSK -TRAILER-SPECIFICATIONS Table 3. Specifications ContDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE 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 - PAGEMicroprocessor Controlled Alarm System DCA-800SSK - GENERAL INFORMATIONDCA-600SSK FAMILIARIZATION Generator Engine Control PanelDCA-800SSK - MAJOR COMPONENTS Table 4. Generator Major ComponentsDESCRIPTION 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 - PAGEDCA-800SSK - OUTPUTTERMINAL OVERVIEW Output Terminal FamiliarizationThe “Output Terminal Panel ” Figure 8 is provided with the following Output Terminal PanelDCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW 120VAC GFCI ReceptaclesFigure 9. G.F.C.I. Receptacle Figure 11. Voltage Regulator Control KnobConnecting Loads Maximum Power Output KWDCA-800SSK - OUTPUT TERMINAL PANEL OVERVIEW Over Current RelaySingle Phase Load Table 13. Power Factor By LoadThree Phase Load DCA-800SSK- LOAD APPLICATIONDCA-800SSK - GENERATOR OUTPUTS Generator OutputVoltagesVoltage Change-Over Board Generator AmperageHow to Read the OutputTerminal Gauge DCA-800SSK - GENERATOR OUTPUTS/GAUGE READINGMaximum Amps Figure 19. AC Ammeter Change-Over SwitchDCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output VoltagesDCA-800SSK - OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480V UVWO Terminal Output Voltages1Ø-480V UVWO Terminal Output Voltages 1Ø-277V UVWO Terminal Output VoltagesDCA-800SSK - PRE-SETUP Circuit BreakersLubrication Oil Fuel CheckRefilling Procedures CAUTION -TRAILER FUELTANKWARNING - RESPIRATORY HAZARDS refuelingCAUTION - REFUELING SECONDARY FUELTANK DCA-800SSK - PRE-SETUPFigure 35. Full Trailer Tank Figure 37. Full Fuel SystemDCA-800SSK- PRE-SETUP Cleaning the RadiatorAir Cleaner Operation Freezing WeatherBattery Battery Cable InstallationCAUTION - BATTERY SERVICING SAFETY WiringDCA-800SSK - GEN. START-UP PROCEDURE MANUAL Before StartingCAUTION - LETHAL EXHAUST HAZARD Generator and Control PanelDCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL 5. Set the battery ON/OFF switch Figure 45 to the “ON” positionFigure 45. Battery ON/OFF Switch Figure 46. Ignition Switch Pre-HeatDCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL Figure 48. Coolant Temperature GaugeFigure 47. Oil Pressure Gauge Figure 50. Main, Aux. and GFCI Circuit Breakers ON20. Set the battery ON/OFF switch Figure 60 to the “ON” position BEFORE STARTING Generator and Control PanelDCA-800SSK - GENERATOR START-UP PROCEDURE MANUAL Figure 62. Engine Speed Switch HighDCA-800SSK - GENERATOR SHUT-DOWN PROCEDURE AUTO CAUTION - BACKUP GENERATOR USEWARNING - AUTO MODE MAINTENANCE 2. Set the battery ON/OFF switch Figure 66 to the “ON” positionDCA-600SSK - GENERATOR SHUT-DOWN PROCEDURE Emergency Shutdown ProcedureWARNING - EMERGENCY STOP SWITCH Engine Shutdown Controller S/N 3698617~DCA-800SSK - MAINTENANCE INSPECTION / MAINTENANCE10 Hrs 250 HrsService Daily Cleaning the Fuel StrainerGeneral Inspection Outer ElementFlushing Out Radiator and Changing Coolant Changing OilReplacing Fuel Filter DCA-800SSK - MAINTENANCECleaning Breather Element GreasingGenerator Storage Removal From Long Term StorageDCA-800SSK - MAINTENANCE NOTEapplied to the generators internal battery chargerFigure 75. Battery Charger/Jacket Water Heater Power Connections DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEBrakes Air Brake SystemS-Cam Brakes Brake Drums or discs, Linings, and HosesDCA-800SSK -TRAILER MAINTENANCE Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD Tire Wear/InflationDCA-800SSK -TRAILER MAINTENANCE Lug NutTorque RequirementsFigure 78. Wheel Lug Nuts Tightening Sequence Table 18. Tire Torque RequirementsDCA-800SSK -TRAILER-WIRING DIAGRAM Figure 79. Trailer Wiring Diagram 5-PinDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK -TRAILER-WIRING DIAGRAM Figure 80. Trailer Wiring Diagram 7-PinDCA-800SSK - GENERATOR WIRING DIAGRAM Figure 81. Generator Wiring DiagramDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - GENERATOR WIRING DIAGRAM MAIN BREAKER Figure 82. Main Circuit Breaker Wiring DiagramDCA-800SSK - ENGINE WIRING DIAGRAM Figure 83. Engine Wiring DiagramDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-800SSK - ENGINE WIRING DIAGRAM Figure 84. Engine Wiring DiagramContinuedDCA-800SSK - ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM Figure 85. Electronic Governor ControllerDCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGE DCA-600SSK -TROUBLESHOOTING ENGINE TABLE 20. ENGINE TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-800SSK -TROUBLESHOOTING ENGINE TABLE 20. ENGINE TROUBLESHOOTING CONTINUEDSYMPTOM POSSIBLE PROBLEMDCA-800SSK -TROUBLESHOOTING GENERATOR/ENGINE TABLE 21. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMDCA-800SSK -TROUBLESHOOTING MPEC TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING MPECSolution SymptonEXPLANATION OF CODE IN REMARKS COLUMN SAMPLE PARTS LISTQTY. Column NO. ColumnDCA-800SSK - SUGGESTED SPARE PARTS DescriptionDCA-800SSKW/KOMATSU SA12V140 DIESEL ENGINE 1TO 3 UNITS 1 to 3 Units DCA-800SSK - GENERATOR ASSY GENERATOR ASSYPART NAME QTY. REMARKSDCA-800SSK - GENERATOR ASSY DCA-800SSK - GENERATOR ASSY DCA-800SSK - GENERATOR ASSY PART NAMEQTY. REMARKS DCA-800SSK - CONTROL PANEL ASSY CONTROL PANEL ASSYDCA-800SSK - CONTROL PANEL ASSY REMARKSPART NAME S/N 3699248~ REPLACESDCA-800SSK - CONTROL BOX ASSY CONTROL BOX ASSYDCA-800SSK - CONTROL BOX ASSY PART NAMEREMARKS S/N 3692434 TO S/NDCA-800SSK - CONTROL BOX ASSY DCA-800SSK - CONTROL BOX ASSY PART NAMEREMARKS CHANGE-OVER BOARD, VOLTAGEDCA-800SSK - ENGINE AND RADIATOR ASSY 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 DCA-800SSK - OIL DRAIN ASSY OIL DRAIN ASSYDCA-800SSK - OIL DRAIN ASSY DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEPART NAME REMARKSDCA-800SSK - ENGINE OPERATING PANEL ASSY 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 DCA-800SSK - OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYDCA-800SSK - OUTPUTTERMINAL ASSY PART NAMEBRACKET, OUTPUT TERMINAL SET BOARD, OUTPUT TERMINALDCA-800SSK - OUTPUTTERMINAL ASSY DCA-800SSK - OUTPUTTERMINAL ASSY PART NAMEREMARKS 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 ASSYDCA-800SSK - FUELTANK ASSY PART NAMEREMARKS CAP, FUEL TANKDCA-800SSK - ENCLOSURE #1 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #1 ASSY PART NAMEENCLOSURE #1 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-800SSK - ENCLOSURE #1 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #1 ASSY PART NAMEREMARKS DCA-800SSK - ENCLOSURE #2 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #2 ASSY PART NAMEENCLOSURE #2 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-800SSK - ENCLOSURE #2 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #2 ASSY PART NAMEREMARKS DCA-800SSK - ENCLOSURE #3 ASSY THE PART NUMBER ABOVE INDICATES DEFAULT COLOROF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #3 ASSY PART NAMEQTY. REMARKS ENCLOSURE #3 ASSYTHE PART NUMBER ABOVE INDICATES DEFAULT COLOR DCA-800SSK - ENCLOSURE #3 ASSYOF ORANGE. TO ORDER WITH DIFFERENT COLOR PLEASE ADD THE FOLLOWING LETTERS WITH THE PART NUMBER MQGR-GRAYDCA-800SSK - ENCLOSURE #3 ASSY PART NAMEDCA-800SSK - RUBBER SEALS ASSY RUBBER SEALS ASSYDCA-800SSK - RUBBER SEALS ASSY PART NAMERUBBER SEALS ASSY DCA-800SSK - NAME PLATE AND DECALS NAME PLATE AND DECALSPROCEDURE GROUP CONTROL PANEL GROUPDCA-800SSK - NAME PLATE AND DECALS PART NAMEDCA-800SSK - NAME PLATE AND DECALS BATTERY GROUP DCA-800SSK - NAME PLATE AND DECALSENGINE & RADIATOR GROUP OIL DRAIN GROUPTERMS AND CONDITIONS OF SALE - PARTS SPECIAL EXPEDITING SERVICEPAYMENT TERMS FREIGHT POLICYNOTE PAGE DCA-800SSK STD - OPERATION AND PARTS MANUAL - REV. #4 06/03/10 - PAGEHERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGMQ Power Contact mqpower@multiquip.com