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Multiquip DCA-800SSK manual

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Table of contents for the manual

  • Page 1

    THIS MANU AL MUST A CCOMP ANY THE EQ UIPMENT A T ALL TIMES. T o find the latest revision of this publication, visit our website at: www .mqpower .com MODEL DCA-800SSK POR T ABLE GENERA TOR (ST ANDARD) Re vision #4 (06/03/10) P ARTS AND OPERA TION MANUAL OPERA TION AND PARTS MANUAL[...]

  • Page 2

    P A GE 2 — DCA-800SSK (STD) — OPERA TION AND P AR TS MANU AL — REV . #4 (06/03/10) Diesel engine exhaust and some of[...]

  • Page 3

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

  • Page 4

    P A GE 4 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK T ABLE OF CONTENTS MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK MQ Power DCA-600SSK AC Generator AC Generator AC Generator AC Generator AC Generator Here's How T o Get Help ......................................[...]

  • Page 5

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 5 P AR TS ORDERING PROCEDURES www .mqpo w e r .com Or dering par ts has never been easier! Choose fr om three easy options: WE A CCEPT ALL MAJOR CREDIT CARDS! When or dering par ts, please supply: R Dealer Account Number R Dealer Name and Address R Shipping Address (if [...]

  • Page 6

    P A GE 6 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — SPECIFICA TIONS s n o i t a c i f i c e p S . 7 e l b a T s n o i t a c i f i c e p S r o t a r e n e G l e d o MK S S 0 0 8 - A C D e p y T s u o n o r h c n y s e p y t d e t c e t o r p n e p o , d e t a l i t n e v f l e s , d l e i f g n i v [...]

  • Page 7

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 7 NO TE P A GE[...]

  • Page 8

    P A GE 8 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — DIMENSIONS (T OP AND SIDE) Figure 1. Dimensions[...]

  • Page 9

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 9 Figure 2. Dimensions DCA-800SSK— DIMENSIONS (FRONT , REAR AND DOORS)[...]

  • Page 10

    P A GE 10 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — SAFETY MESSA GE ALERT SYMBOLS Bef ore using this g enerator , ensure that the operating individual has read and understands all instructions in this manual. Safety precautions should be followed at all times when operating this equipment. F ailur[...]

  • Page 11

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 11 DCA-800SSK — SAFETY MESSA GE ALER T SYMBOLS AL W A YS place the engine ON/OFF switch in the OFF position when the generator is not in use. AL W A YS wear appro v ed respiratory protection. AL W A YS wear approv ed eye and hearing protection. Other impor tant messag[...]

  • Page 12

    P A GE 12 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — R ULES FOR SAFE OPERA TION The following safety guidelines should always be used when operating the DCA-800SSK (60 Hz) Whisperwatt ™ Generator General Safety: ■ DO NO T operate or ser vice this equipment before reading this entire manual. The[...]

  • Page 13

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 13 DCA-800SSK — R ULES FOR SAFE OPERA TION POWER CORD (POWER ON) WET HANDS Dur ing operation of this gener ator , there exists the possibility of electrocution, electrical shock or burn, which can cause se vere bodily harm or e ven DEA TH! T o a v oid these hazards: N[...]

  • Page 14

    P A GE 14 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — R ULES FOR SAFE OPERA TION Battery Safety Use the following guidelines when handling the battery: ■ The battery contains acids that can cause injur y to the ey es and skin. T o avoid eye irritation, always wear safety glasses. ■ Use well insu[...]

  • Page 15

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 15 Emergencies ■ AL W A YS know the location of the nearest fire extinguisher . ■ AL W A YS know the location of the nearest and first aid kit . ■ AL W A YS know the location of the nearest phone or keep a phone on the job site, in case of emergencies. ■ AL W A [...]

  • Page 16

    P A GE 16 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Figure 3. T ypical Generator Grounding Application DCA-600SSK — INST ALLA TION DCA-800SSK — INST ALLA TION[...]

  • Page 17

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 17 Outdoor Installation Install the generator in a area that is free of debris , bystanders , and overhead obstructions . Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaus[...]

  • Page 18

    P A GE 18 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) T o reduce the possibility of an accident while transpor ting the generator on public roads, always make sure the trailer (Figure 4) that suppor ts the generator and the to wing v ehicle are in good operating condition and both units are mechanically sound. The[...]

  • Page 19

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 19 Explanation of Chart: This section is intended to provide the user with trailer ser- vice and maintenance inf ormation. The ser vice and mainte- nance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer wi[...]

  • Page 20

    P A GE 20 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — TRAILER-SPECIFICA TIONS s n o i t a c i f i c e p S r e l i a r T . 3 e l b a T L E D O M N O I T A C I L P P A L L E C L E U F M E T S Y S E K A R B R W V G E M A R F H T G N E L E M A R F H T D I W K C A J D N A T S W 0 1 - R L R T , 5 2 2 W D [...]

  • Page 21

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 21 DCA-800SSK — TRAILER-SPECIFICA TIONS ) t ' n o C ( s n o i t a c i f i c e p S . 3 e l b a T L E D O M R E L P U O C S E R I T S L E E H W E L X A S B U H N O I S N E P S U S L A C I R T C E L E W 0 1 - R L R T S S A L C L L A B " 2 E L B A T S U J D A 2 [...]

  • Page 22

    P A GE 22 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Machine Safety Decals The DCA-800SSK generator is equipped with a n umber of saf ety decals. These decals are provided f or operator saf ety and maintenance inf or mation. The illustrations below and on the preceding pages sho ws the decals as they appear on th[...]

  • Page 23

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 23 DCA-800SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 24

    P A GE 24 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 25

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 25 DCA-800SSK — OPERA TION AND SAFETY DECALS[...]

  • Page 26

    P A GE 26 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — GENERAL INFORMA TION DCA-600SSK F AMILIARIZA TION Generator The MQ P ower Model DCA-800SSK is a 640 kW generator that has been designed as a high quality por table (requires a trailer f or transpor t) pow er source f or telecom sites , lighting f[...]

  • Page 27

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 27 DCA-600SSK — MAJOR COMPONENTS DCA-800SSK — MAJOR COMPONENTS 4 e l b a T . s t n e n o p m o C r o j a M r o t a r e n e G . O N M E T IN O I T P I R C S E D 1y l b m e s s A r o t a r e n e G 2y l b m e s s A l e n a P l o r t n o C r o t a r e n e G 3y l b m e s[...]

  • Page 28

    P A GE 28 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Figure 6. Generator Control Panel DCA-800SSK — GENERA T OR CONTR OL P ANEL Up to S/N 3699247 S/N 3699248~[...]

  • Page 29

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 29 DCA-800SSK — GENERA T OR CONTR OL P ANEL The definitions below describe the controls and functions of the DCA-800SSK " Control Panels " (Figure 9). 1 . Cir cuit Breaker OFF lamp - This indicates the main circuit breaker is "OFF" and the generato[...]

  • Page 30

    P A GE 30 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENGINE OPERA TING P ANEL Figure 7. Engine Operating Panels Up to S/N 3699247 S/N 3699248~[...]

  • Page 31

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 31 8. T achometer - Indicates engine speed in RPMs f or 60Hz operation. Normal operation is 1800 RPMs when the load is applied. A built in hour meter will record the number of operational hours that the generator has been in use. 8 . Oil Pressure gauge - This gauge indi[...]

  • Page 32

    P A GE 32 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — OUTPUT TERMINAL O VER VIEW Figure 8. Output T erminal Panel Output T erminal F amiliarization The “ Output T erminal P anel ” (Figure 8) is provided with the following:  Three 240/139V output receptacles, 50 amp  Three A UX. circuit bre[...]

  • Page 33

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 33 DCA-800SSK — OUTPUT TERMINAL P ANEL O VER VIEW 120 V A C GFCI Receptac les There are two 120 V AC , 20 amp GFCI (Duple x Nema 5-20R) recepacles pro vided on the output ter minal panel. These receptacles can be accessed in any voltage change-over board position. Eac[...]

  • Page 34

    P A GE 34 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — OUTPUT TERMINAL P ANEL O VER VIEW Figure 13. Connecting Loads Connecting Loads Loads can be connected to the generator by the UVWO terminal lugs or the convenience receptacles. (See Figure 13). Make sure to read the operation manual before attemp[...]

  • Page 35

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 35 DCA-800SSK— LO AD APPLICA TION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment. Generally , th[...]

  • Page 36

    P A GE 36 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Generator Output V oltages A wide range of voltages are available to supply voltage for many diff erent applications. V oltages are selected by apply- ing jumpers (6) to the voltage change-over board (Figure 15). T o obtain some of the v oltages as listed in T [...]

  • Page 37

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 37 DCA-800SSK — GENERA T OR OUTPUTS/GA UGE READING How to Read the Output T erminal Gauge . The AC ammeter and AC voltmeter change-over switches on the control panel DO NO T eff ect the generator output. They are provided to help observe how much power is being suppli[...]

  • Page 38

    P A GE 38 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Figure 21. V oltage Change-Over Board 240V Configuration DCA-800SSK — OUTPUT TERMINAL P ANEL CONNECTIONS UVWO T erminal Output V oltages V ar ious output voltages can be obtained using the UVW O output ter minal lugs. The v oltages at the ter minals are de- p[...]

  • Page 39

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 39 2. Connect the load wires to the UVWO terminals as shown in Figure 27. DCA-800SSK — OUTPUT TERMINAL P ANEL CONNECTIONS 3Ø-480V UVW O T erminal Output V oltages 1 . Jumper the voltage change-over board for 480V operation as shown in Figure 26. This configuration us[...]

  • Page 40

    P A GE 40 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Lubrication Oil Fill the engine crankcase with lubricating oil through the filler hole, b ut DO NO T ov erfill. Mak e sure the generator is le vel. Also verify that the oil level is maintained between the two notches (Figure 30) on the dipstic k. See T able 11 [...]

  • Page 41

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 41 DCA-800SSK — PRE-SETUP 1. Le vel T anks – make sure fuel cells are le v el with the ground. F ailure to do so will cause fuel to spill from the tank bef ore reaching full capacity . See Figure 33. 2. T railer Fuel T ank First – The trailer fuel tank is the prim[...]

  • Page 42

    P A GE 42 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — PRE-SETUP 3. NEVER o verfill trailer fuel tank – It is impor tant to read the trailer fuel gauge when filling trailer fuel tank. DO NO T wait f or fuel to r ise in filler nec k. See Figure 35. Figure 35. Full T railer T ank Figure 36. Filling S[...]

  • Page 43

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 43 Coolant (Eth ylane Gl ycol [Green] / W ater — 50/50 mix) Use only drinkable tap w ater . If hard water or w ater with many impurities is used, the inside of the engine and radiator may become coated with deposits and cooling efficiency will be reduced. An anticorro[...]

  • Page 44

    P A GE 44 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK— PRE-SETUP When connecting battery do the following: 1. NEVER connect the battery cables to the battery terminals when the ignition switch is in either the Pre- Heat, R UN, or ST AR T position. AL W A YS make sure that the ignition s witch is in th[...]

  • Page 45

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 45 DCA-800SSK — GEN. ST ART -UP PROCEDURE (MANU AL) If applicable perform the following: ■ Apply commercial power to the internal battery charger receptacle (to ensure good star ting) via commercial power . An e xter nal pow er cord will be required. This capability[...]

  • Page 46

    P A GE 46 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — GENERA T OR ST AR T -UP PR OCEDURE (MANU AL) Figure 52. V oltage Adjust Control Knob Figure 53. Ammeter (No Load) 13. The ammeter (Figure 53) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amou[...]

  • Page 47

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 47 14. The engine oil pressure gauge (Figure 47) will indicate the oil pressure (kg/ cm 2 ) of the engine. Under normal operating conditions the oil pressure is approximately Figure 47. Oil Pressure Gauge Figure 49. Engine T achometer Gauge 16 . The tachometer gauge (Fi[...]

  • Page 48

    P A GE 48 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Steps 20 thru 26 are referenced f o r Engine Operating P anel S /N 3699248~. See Figure 59 b e low . This panel does not ha v e an ignition switch. It does have a “ pre-heat button ” and a “ en- gine speed switch ” that is used in conjunction with the M[...]

  • Page 49

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 49 DCA-800SSK — GENERA T OR SHUT -DO WN PR OCEDURE (A UT O) When star ting generator in AU T O mode use the " Manual Start-up " procedure except where noted (see below). 1. P erform steps 1 through 4 in the Bef ore Star ting section (page 45) as outlined in [...]

  • Page 50

    P A GE 50 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Figure 71. Ignition Ke y Switch (ST OP position) Engine Shutdown Ignition Key (Up to S/N 3699247) T o shutdown the gener ator use the f ollo wing procedure: 1. Place both the MAIN , GFCI and LO AD circuit break ers (Figure 69) to the " OFF position". [...]

  • Page 51

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 51 Use T ab le 14 shown belo w as a general checklist to be performed on a daily basis. DCA-800SSK — MAINTENANCE . 4 1 E L B A T E C N A N E T N I A M / N O I T C E P S N I s r H 0 1 Y L I A D s r H 0 5 2 s r H 0 0 5 s r H 0 0 0 1 E N I G N E s l e v e L d i u l F e n[...]

  • Page 52

    P A GE 52 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — MAINTENANCE General Inspection Prior to each use, the generating set should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel or oil leaks. Air Cleaner Ev er y 50 ho[...]

  • Page 53

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 53 14. Drain the water inside reserve tank, clean the inside of the reserve tank, then fill with coolant/water mixture to between the full and low lines. 15. Stop the engine, wait for 3 minutes, add tap water until the water le v el reaches near the w ater filer por t, [...]

  • Page 54

    P A GE 54 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Generator Storage: For storage of the generator for over 30 days, the following is required:  Fill the fuel tank completely . T reat with fuel stabiliz er if necessar y .  Completely drain oil from the crankcase and refill if necessary with fresh oil. [...]

  • Page 55

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 55 Jac ket W ater Heater and Internal Batter y Charger 120 V A C Input Receptacles (OPTIONAL) This generator is equipped with two 120 V A C , 20 amp input receptacles located on the output terminal panel. The purpose of these receptacles is to provide power via commerci[...]

  • Page 56

    P A GE 56 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Figure 76. Hydraulic Brake Components Brakes T railer brak es should be inspected the first 200 miles of operation. This will allow the bra ke shoes and drums to seat proper ly . After the first 200 mile inter v al, inspect the brak es every 3,000 miles . If dr[...]

  • Page 57

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 57 Tires/Wheels/Lug Nuts Tires and wheels are a v er y impor tant and cr itical components of the trailer . When specifying or replacing the trailer wheels it is impor tant the wheels, tires , and axle are properly matched. Tire W ear/Inflation Tire inflation pressure i[...]

  • Page 58

    P A GE 58 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) Lug Nut T orque Requirements It is e xtremely impor tant to apply and maintain proper wheel mounting torque on the trailer . Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1[...]

  • Page 59

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 59 DCA-800SSK — TRAILER-WIRING DIA GRAM Figure 79. T railer Wiring Diagram (5-Pin)[...]

  • Page 60

    P A GE 60 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — TRAILER-WIRING DIA GRAM Figure 80. T railer Wiring Diagram (7-Pin)[...]

  • Page 61

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 61 DCA-800SSK — GENERA T OR WIRING DIA GRAM Figure 81. Generator Wiring Diagram[...]

  • Page 62

    P A GE 62 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — GENERA T OR WIRING DIA GRAM (MAIN BREAKER) Figure 82. Main Circuit Breaker Wiring Diagram[...]

  • Page 63

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 63 DCA-800SSK — ENGINE WIRING DIA GRAM Figure 83. Engine Wiring Diagram[...]

  • Page 64

    P A GE 64 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENGINE WIRING DIA GRAM Figure 84. Engine Wiring Diagram(Continued)[...]

  • Page 65

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 65 DCA-800SSK — ELECTR ONIC GO V . CONTR OLLER WIRING DIA GRAM Figure 85. Electronic Governor Controller[...]

  • Page 66

    P A GE 66 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-600SSK — TR OUBLESHOO TING (ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use T able 20 (Engine T roubleshooting) as a basic guideline f or troubleshooting the engine .[...]

  • Page 67

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 67 DCA-800SSK — TR OUBLESHOO TING (ENGINE) ) D E U N I T N O C ( G N I T O O H S E L B U O R T E N I G N E . 0 2 E L B A T M O T P M Y S M E L B O R P E L B I S S O P N O I T U L O S t o n s i n o i t u l o v e r e n i g n E . h t o o m s ? y t r i d r o d e g g o l c[...]

  • Page 68

    P A GE 68 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — TR OUBLESHOO TING (GENERA T OR/ENGINE) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use T able 21 (Gener ator T roub leshooting) as a basic guideline f or troub lesho[...]

  • Page 69

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 69 DCA-800SSK — TR OUBLESHOO TING (MPEC) Use T ab le 22 (Engine Controller T roubleshooting) as a basic guideline f or troub leshooting the MPEC . If the prob lem cannot be remedied, consult our company's business office or service plant. ) C E P M ( G N I T O O [...]

  • Page 70

    P A GE 70 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) EXPLANA TION OF CODE IN REMARKS COLUMN The f ollowing section e xplains the diff erent symbols and remarks used in the P ar ts section of this manual. Use the help numbers f ound on the back page of the manual if there are any questions . SAMPLE P AR TS LIST NO[...]

  • Page 71

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 71 DCA-800SSK W/K OMA TSU SA12V140 DIESEL ENGINE 1 T O 3 UNITS 1 to 3 Units Qty . P /N Description 6 ....... 5610262520 ...................... AIR FIL TER, INNER 1 2 ..... 5610262530 ...................... AIR FIL TER, OUTER 1 2 ..... 6003117111 ...................... F[...]

  • Page 72

    P A GE 72 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) GENERA T OR ASSY . DCA-800SSK — GENERA T OR ASSY .[...]

  • Page 73

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 73 DCA-800SSK — GENERA T OR ASSY . GENERA T OR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5110000102 ROT O R ASSY . .......................................... 1 ......... INCLUDE ITEMS W/ * 1-1 * FIELD ASSY . 1 1-2 * 0601842366 RESIST OR ........................[...]

  • Page 74

    P A GE 74 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — GENERA T OR ASSY . GENERA T OR ASSY .[...]

  • Page 75

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 75 DCA-800SSK — GENERA T OR ASSY . GENERA T OR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 4 C5153000002 END BRACKET 1 5 C4137000003 FIELD ASSY ., EXCITER 1 6 0012110075 HEX. HEAD BOL T 6 6 0042610000 LOCK W ASHER 6 6 0041210000 PLAIN W ASHER 6 7 0845044904 GROMMET [...]

  • Page 76

    P A GE 76 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — CONTR OL P ANEL ASSY . CONTR OL P ANEL ASSY .[...]

  • Page 77

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 77 DCA-800SSK — CONTR OL P ANEL ASSY . CONTR OL P ANEL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5224000503 CONTR OL P ANEL 1 2 C5224000403 CONTR OL P ANEL 1 3 0605011211 P I N 4 4 0601810476 OFF LAMP , CIRCUIT BREAKER ............ 1 ....... APN133-G 4 06018102[...]

  • Page 78

    P A GE 78 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — CONTR OL BO X ASSY . CONTR OL BO X ASSY .[...]

  • Page 79

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 79 DCA-800SSK — CONTR OL BO X ASSY . CONTR OL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5214000002 CONTR OL BO X ........................................ 1 ......... S/N 3692434 T O S/N 3706720 1 C52140100502 CONTR OL BO X .................................[...]

  • Page 80

    P A GE 80 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — CONTR OL BO X ASSY . CONTR OL BO X ASSY .[...]

  • Page 81

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 81 DCA-800SSK — CONTR OL BO X ASSY . CONTR OL BO X ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 34 0601823757 RELA Y , MY2DC24V 1 UPT O S/N 3698625 34 0601823143 SOCKET , PYF08A 1 UPT O S/N 3698625 3 4 PYCA1 HOLDER 1 REPLACES 0601824400 34 0601823732 RELA Y , L Y2DC2[...]

  • Page 82

    P A GE 82 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY .[...]

  • Page 83

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 83 DCA-800SSK — ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5924200024 ENGINE, K OMA TSU SA12V140 .............. 1 ......... T O S/N 3700267 1 C5924200024 ENGINE, K OMA TSU SA12V140E ............ 1 ......... S/N [...]

  • Page 84

    P A GE 84 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY .[...]

  • Page 85

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 85 DCA-800SSK — ENGINE AND RADIA T OR ASSY . ENGINE AND RADIA T OR ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 37 6001813960 C A P , AIR CLEANER ................................ 2 ......... REPLACES 0602040752 38 6215114410 BR A CKET , AIR CLEANER ..................[...]

  • Page 86

    P A GE 86 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — OIL DRAIN ASSY . OIL DRAIN ASSY .[...]

  • Page 87

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 87 DCA-800SSK — OIL DRAIN ASSY . OIL DRAIN ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 0602023160 PUMP ............................................................. 1 .......... GM-2524H 2 0017108040 HEX. HEAD BOL T 4 2 0207008000 HEX. NUT 4 3 0131710060 BUSHING, [...]

  • Page 88

    P A GE 88 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENGINE OPERA TING P ANEL ASSY . ENGINE OPERA TING P ANEL ASSY .[...]

  • Page 89

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 89 DCA-800SSK — ENGINE OPERA TING P ANEL ASSY . ENGINE OPERA TING P ANEL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5484000002 SUPPORT LEG 1 2 0017112045 HEX. HEAD BOL T 4 2 0030012000 HEX. NUT 4 2 0041212000 PLAIN W ASHER 4 3 0017110025 HEX. HEAD BOL T 2 3 0207[...]

  • Page 90

    P A GE 90 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY .[...]

  • Page 91

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 91 DCA-800SSK — OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5231700003 SET BOARD , OUTPUT TERMINAL 1 2 7521860504 O U TPUT TERMINAL 4 3 7521850504 B R A CKET , OUTPUT TERMINAL 4 4 0010112040 HEX. HEAD BOL T 8 4 0030012000 HE[...]

  • Page 92

    P A GE 92 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) OUTPUT TERMINAL ASSY . DCA-800SSK — OUTPUT TERMINAL ASSY .[...]

  • Page 93

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 93 OUTPUT TERMINAL ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 25 0030012000 HEX. NUT 4 26 7521865603 ST OPPER 1 27 0010108030 HEX. HEAD BOL T 1 27 0030008000 HEX. NUT 1 27 0041208000 PLAIN W ASHER 2 28 C4237100504 CO V ER 1 29 0017108020 HEX. HEAD BOL T 5 30 06018058[...]

  • Page 94

    P A GE 94 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — B A TTER Y ASSY . BA TTER Y ASSY .[...]

  • Page 95

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 95 DCA-800SSK — B A TTER Y ASSY . BA TTER Y ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 0168719052 B A TTER Y 4 2 0805018904 BA T T E R Y SHEET 4 3 0805006404 BA T T E R Y BAND 2 4 0805006504 BA T T E R Y B O L T 4 5 0037808000 WING NUT 4 6 0040008000 LOCK W ASHER[...]

  • Page 96

    P A GE 96 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) MUFFLER ASSY . DCA-800SSK — MUFFLER ASSY .[...]

  • Page 97

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 97 DCA-800SSK — MUFFLER ASSY . MUFFLER ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5331100002 MUFFLER 1 2 0019112030 HEX. HEAD BOL T 4 2 0042312000 LOCK W ASHER 4 2 0042412000 PLAIN W ASHER 4 3 C5335200104 P A CKING 2 4 C5335200204 P A CKING 1 5 C5335200304 P A C[...]

  • Page 98

    P A GE 98 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) FUEL T ANK ASSY . DCA-800SSK — FUEL T ANK ASSY .[...]

  • Page 99

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 99 DCA-800SSK — FUEL T ANK ASSY . FUEL T ANK ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5364000303 FUEL T ANK 1 2 0605505030 C A P , FUEL T ANK ..................................... 1 ......... REPLACES 0605505005 2 A 0601850590 K EY , FUEL T ANK CAP 1 3 0810105[...]

  • Page 100

    P A GE 100 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENCLOSURE #1 ASSY . ENCLOSURE #1 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF A UL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 101

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 101 ENCLOSURE #1 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5414000002 BASE 1 2 7525116004 FLOOR P ANEL 1 3 0019110030 HEX. HEAD BOL T 4 3 0042310000 LOCK W ASHER 4 3 0042410000 PLAIN W ASHER 4 4 C5414100004 FLOOR P ANEL 1 5 0019208020 HEX. HEAD BOL T 1 2 6 C54146[...]

  • Page 102

    P A GE 102 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENCLOSURE #1 ASSY . ENCLOSURE #1 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-GR[...]

  • Page 103

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 103 DCA-800SSK — ENCLOSURE #1 ASSY . ENCLOSURE #1 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 31 C5424200103 CO VER, FR ONT FRAME 1 32 C5424200203 CO VER, FR ONT FRAME 1 33 0019208020 HEX. HEAD BOL T 1 6 34 C5434000002 CENTER FRAME 1 35 0010120075 HEX. HEAD BOL T 6 [...]

  • Page 104

    P A GE 104 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) ENCLOSURE #2 ASSY . DCA-800SSK — ENCLOSURE #2 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-GR[...]

  • Page 105

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 105 ENCLOSURE #2 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5444000313 REAR FRAME 1 1 C5494300104 LINING 1 2 7525151004 LOUVER P ANEL 5 3 0207006000 NEX. NUT 4 0 4 C5444000203 REAR FRAME 1 4 C5494300004 LINING 1 5 C5444000003 REAR FRAME 1 5 C5494300004 LINING 1 6 [...]

  • Page 106

    P A GE 106 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENCLOSURE #2 ASSY . ENCLOSURE #2 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF A UL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 107

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 107 DCA-800SSK — ENCLOSURE #2 ASSY . ENCLOSURE #2 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 29 0805011304 ST OPPER, DOOR 1 30 0805011204 ST OPPER, DOOR 1 31 0205006000 HEX. NUT 4 31 0042306000 LOCK W ASHER 4 31 0042406000 PLAIN W ASHER 4 3 2 M9110100204 HINGE ....[...]

  • Page 108

    P A GE 108 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) ENCLOSURE #3 ASSY . DCA-800SSK — ENCLOSURE #3 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF A UL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-G[...]

  • Page 109

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 109 ENCLOSURE #3 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 C5454200403 SPLASHER P ANEL .................................. 1 ......... S/N 3692434 T O 3700698 1 C5454200413 SPLASHER P ANEL .................................. 1 ......... S/N 3700699 T O 3706720 1 C54[...]

  • Page 110

    P A GE 110 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — ENCLOSURE #3 ASSY . ENCLOSURE #3 ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . THE P ART NUMBER ABO VE INDICA TES DEF AUL T COLOR OF ORANGE. TO ORDER WITH DIFFERENT COLOR, PLEASE ADD THE FOLLOWING LETTERS WITH THE P ART NUMBER: MQGR-GRA Y MQGRN-GR[...]

  • Page 111

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 111 DCA-800SSK — ENCLOSURE #3 ASSY . ENCLOSURE #3 ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 24 7525176704 DUCT 1 24 7525966704 LINING 1 25 0019208020 HEX. HEAD BOL T 5 8 26 0825007362 DOOR HANDLE 3 27 0021806016 MACHINE SCREW 1 2 28 0845046904 HINGE 1 1 28 0845045[...]

  • Page 112

    P A GE 112 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — R UBBER SEALS ASSY . R UBBER SEALS ASSY .[...]

  • Page 113

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 113 DCA-800SSK — R UBBER SEALS ASSY . R UBBER SEALS ASSY . NO P AR T NO P AR T NAME QTY . REMARKS 1 0228901690 R UBBER SEAL 8 2 0228900995 R UBBER SEAL 4 3 0228901035 R UBBER SEAL 4 4 0228901090 R UBBER SEAL 2 5 0229201950 R UBBER SEAL 2 6 0228801030 R UBBER SEAL 2 7 [...]

  • Page 114

    P A GE 114 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — NAME PLA TE AND DECALS NAME PLA TE AND DECALS[...]

  • Page 115

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 115 DCA-800SSK — NAME PLA TE AND DECALS NAME PLA TE AND DECALS NO P AR T NO P AR T NAME QTY . REMARKS CONTROL P ANEL GROUP 1 0800520904 PL A T E ; ON-OFF ............................................ 1 ....... A T -202 2 0800520904 PL A T E ; AMMETER CHANGE-O VER SWITC[...]

  • Page 116

    P A GE 116 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) DCA-800SSK — NAME PLA TE AND DECALS NAME PLA TE AND DECALS[...]

  • Page 117

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 117 DCA-800SSK — NAME PLA TE AND DECALS NO P AR T NO P AR T NAME QTY . REMARKS ENGINE & RADIA T OR GROUP 2 9 0800689204 DECAL; COOLING W A TER ................................. 1 ........ S -9 6 1 3 0 B9504000304 DECAL; CA UTION HO T P ARTS .......................[...]

  • Page 118

    P A GE 118 — DCA-800SSK (STD) — OPERA TION AND P ARTS MANU AL — REV . #4 (06/03/10) TERMS AND CONDITIONS OF SALE — P AR TS P A YMENT TERM S T erms of payment for parts are net 3 0 days. FREIGHT P OLIC Y All parts orders will be shipped collect or prepaid with the c harges ad ded to the invoice. All shipments are F .O .B. point of origin. Mu[...]

  • Page 119

    DCA-800SSK (STD) — OPERATION AND PARTS MANUAL — REV. #4 (06/03/10) — PAGE 119 NO TE P A GE[...]

  • Page 120

    OPERA TION AND PARTS MANUAL Y our Local Dealer is: HERE’S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2010, MUL TIQUIP INC. MQ P ow er and the MQ P ow er logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written per mission. All other trademarks are [...]